Book your intrinsically safe design consultation
Speak to us about your hazardous area product or technical challenge. Our engineers will help define your initial requirements, review suitable protection concepts, and outline the most practical route to a compliant, manufacturable solution.
- Early-stage guidance on intrinsic safety and protection concept selection
- Feasibility input on power, sensing and wireless system design
- Clear next steps towards certification and manufacturing
Book your free consultation to assess your requirements and move your project forward with confidence.
Book a free consultation
Talk to our intrinsically safe design engineers today – book your free consultation.
Intrinsically safe IoT design from concept to production
We design and develop intrinsically safe connected IoT devices for hazardous areas, combining low power sensing, wireless communication and compliance expertise. From early-stage requirements and protection concept selection through to certification and manufacturing, we provide a clear, structured path to a compliant, production-ready product.
Intrinsically Safe Device Design
Energy-limited electronics designed for safe operation in hazardous areas.
Next-Generation IoT & Wireless
Designed with BLE, Wi-Fi, LoRa, NFC and modern low power communication technologies.
Compliance & Certification
Structured support to achieve ATEX and IECEx approval with confidence.
Manufacturing Support
Design for manufacture and production support from prototype to scale.
Intrinsically safe IoT, engineered for the next generation of hazardous area products
Most hazardous area equipment wasn’t designed for connectivity, low power operation, or modern data-driven use cases. We help bridge that gap, turning concepts and legacy systems into next-generation, intrinsically safe IoT devices built for real-world deployment.
Our focus is on ultra low power sensing and modern wireless communication, enabling reliable data capture in environments where safety, battery life and robustness are critical. Whether you’re developing a new product or upgrading an existing design, we define the right architecture and protection approach from the outset.
We support the full journey from concept through to ATEX and IECEx certification and production, ensuring your product is not only compliant, but engineered to perform in demanding industrial environments.
We typically help clients to:
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Turn concepts into intrinsically safe IoT devices for Zone 0, 1 and 2
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Upgrade existing equipment with low power sensing and wireless connectivity
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Design battery-powered systems for long-term deployment in the field
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Integrate BLE, Wi-Fi, LoRa, NFC and emerging technologies
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Develop products that are ready for certification, manufacture and scale
What our clients say
Book a free consultation
Talk to our electronic design engineers today – book your free consultation
Engineering the next generation of intrinsically safe IoT devices
Most hazardous area systems were never designed for connectivity, low power operation, or modern data-driven use. Today’s environments demand more, with intelligent sensing, edge decision-making, and reliable wireless communication operating safely in Zone 0, Zone 1 and Zone 2.
We design intrinsically safe devices that combine ultra low power sensing, embedded intelligence, and modern wireless technologies, enabling systems to not just collect data, but process it at the edge and act on it in real time. This reduces reliance on infrastructure, improves responsiveness, and unlocks new capabilities in environments where safety and reliability are critical.
Whether developing new intrinsically safe products, upgrading existing equipment with low power sensing and wireless connectivity, or adapting non-intrinsically safe designs for use in hazardous areas, we define the right architecture, protection concept, and system design from the outset.
This approach is particularly relevant in industries such as oil and gas, chemical processing, mining, food and grain handling, pharmaceutical manufacturing, and water and utilities, where hazardous environments and operational risk demand more capable, connected systems.
By managing the full development process in-house, we ensure tight integration between electronics, firmware, wireless systems and compliance, reducing risk and accelerating your path to certification and production.
Specialist Knowledge
Expertise in intrinsically safe design, low power systems and wireless IoT.
Integrated Engineering
Electronics, firmware and compliance developed together from the outset.
Certification Support
Hands-on with test houses and navigating ATEX and IECEx.
Reduced Risk
Early design decisions that minimise rework and certification delays.
Explore our projects
Controller for subsea exploration designed and delivered in low-volume batches on a fast turnaround.
CASE STUDY | Marine, Subsea, Energy
MESH GLOBAL
Custom water level sensor for monitoring arctic glacial melt to support world-class research institution.
CASE STUDY | Marine, Monitoring
AARHUS UNIVERSITY
Custom firmware for multi-mode NFC reader/writer supporting encrypted ticketing and tag emulation.
CASE STUDY | IoT, Wireless
SMART IMPACT
Expert solutions for highly regulated industries
Aerospace
Hazardous locations
Automotive
Defence
Medical
Energy
IoT
Subsea
Trusted by global leaders to deliver world-class design
Book your Intrinsically Safe Design consultation with our team
Talk to an expert about your Intrinsically Safe design requirements now. Our design team are ready to discuss your requirements, answer your questions and review your designs. Get free, expert advice via an introductory video call or an in-person meeting now.
FAQ’s
What is intrinsically safe design?
Intrinsically safe design refers to creating products that can safely operate in hazardous environments without causing ignition. It focuses on reducing the energy available to the system to ensure explosions can’t occur.
Why is intrinsically safe design important?
It’s crucial for ensuring the safety of products used in potentially explosive atmospheres. Ensuring a product’s intrinsic safety can prevent accidents, safeguarding both the users and the environment.
How do products achieve intrinsically safe design?
Products achieve this by limiting the energy available within the system, ensuring it’s too low to ignite explosive gases or dust. This is done through design considerations and protective measures.
When should intrinsically safe design be considered?
It should be considered for any product intended to be used in an environment with a potential risk of gas, vapour, or dust explosions. Such environments can be found in industries like health tech, clean technology, and IoT.
Who regulates intrinsically safe design standards?
There are various international and national bodies that set standards and regulations for intrinsically safe designs. In the UK, one of the primary bodies is the Health and Safety Executive (HSE).
Which industries require intrinsically safe designs the most?
Industries operating in environments with a potential risk of explosions, such as the petrochemical, mining, pharmaceuticals, and agriculture sectors, heavily rely on intrinsically safe designs. These designs ensure that devices and systems within these sectors don’t ignite flammable gases, vapours, or dusts, thus prioritising safety and reducing the risk of catastrophic events.
What are the benefits of intrinsically safe design?
Ensuring intrinsic safety means products can be reliably used in hazardous environments without causing ignition. This reliability can save businesses from potential liabilities and protect users from harm.
How is intrinsically safe design different from explosion-proof design?
While both ensure safety in explosive environments, intrinsically safe design prevents explosions by limiting energy, while explosion-proof design contains and isolates any potential explosions within a robust enclosure.
Why do some industries not use intrinsically safe designs?
Not all environments pose a risk of explosion. Industries without such risks may not require the specific considerations of intrinsically safe design.
Who can evaluate a product for intrinsically safe design?
Specialised regulatory bodies and independent testing organisations can evaluate products for intrinsic safety. In the UK, this would typically be under guidelines set by the HSE.
Which components are crucial in an intrinsically safe system?
Important components include barriers to limit voltage and current, protective circuitry, and specialised materials that prevent spark or heat generation.
When did intrinsically safe design principles originate?
The principles have evolved over many years as industries recognised the need for safety in explosive environments. The formalisation of these principles into standards and guidelines has been a more recent development in the broader context of industrial safety.
How do companies ensure ongoing intrinsically safe operation?
Companies implement regular maintenance checks, periodic testing, and continuous training to ensure that the designed safety measures remain effective throughout the product’s lifecycle.
What challenges are faced in intrinsically safe design?
Challenges include staying updated with changing regulations, ensuring all components meet safety standards, and balancing functional requirements with safety considerations.
Which tests are crucial for intrinsically safe design validation?
Hazard analysis, risk assessment, environment testing, and compliance testing are vital to validate a product’s intrinsic safety.
How are intrinsically safe devices marked?
Devices that are certified as intrinsically safe usually bear specific markings or labels, indicating their compliance with the relevant standards and their suitability for specified hazardous environments.
What are the consequences of not adhering to intrinsically safe design?
Failure to adhere can lead to catastrophic accidents, financial liabilities, and legal consequences. Furthermore, it can jeopardise the safety of users and the environment.
Why are there different intrinsically safe design standards?
Different regions and industries have unique environmental and operational requirements. Therefore, standards are developed to address these specific needs, ensuring products are safe for their intended use.
Who is responsible for ensuring a product's intrinsic safety?
While design and manufacturing companies play a primary role, ensuring intrinsic safety is a collective responsibility, involving regulatory bodies, testing organisations, and end-users.
What are the primary considerations in intrinsically safe design?
Intrinsically safe design prioritises limiting electrical and thermal energy to ensure that devices cannot ignite a flammable atmosphere. This often involves the use of energy-limiting components, barriers, and safe separation distances
How are components selected for intrinsically safe design?
Components for intrinsically safe design are chosen based on their ability to operate safely within defined energy parameters. They should not produce sparks or get hot enough to cause ignition, and their specifications must match the defined safety parameters for the intended environment.
Which standards guide intrinsically safe design requirements?
Intrinsically safe design requirements are often guided by international standards such as IEC 60079 and regional standards like ATEX in Europe. These standards provide detailed guidelines on designing equipment for explosive atmospheres.
Why are energy-limiting devices crucial in intrinsically safe design?
Energy-limiting devices are essential because they restrict the electrical energy in a circuit, ensuring it remains below the level that can ignite a particular gas or dust. This ensures that even in the event of a fault condition, the environment remains safe.
When designing for intrinsically safe environments, what considerations are given to potential fault conditions?
In intrinsically safe design, consideration for potential fault conditions is paramount. The design must ensure that even in the event of faults like short circuits or component failures, the electrical and thermal energy remains below ignition-capable levels for the specific hazardous environment.















