My First Day as an Apprentice Environmental Test Technician

It was September 2013 and at 17 years old, I was stepping into the world of environmental testing for the first time. My first assignment? A water ingress test to IPX6, following the specifications of ISO 60529. Excitement mixed with nerves as I prepared for the challenge, eager to learn the ropes.

Understanding the Test: What is IPX6?
IPX6 evaluates a product’s resistance to water ingress from powerful jets. The ‘X’ indicates that dust resistance isn’t tested, while ‘6’ signifies protection against high-pressure water jets from all practical directions. This level of testing is essential for ensuring reliability and safety in applications where water exposure could pose a risk.

Under the guidance of Colin, one of the senior technicians, I was about to see the process first-hand.

Setting Up the Test
“Calibrated bucket?”
“Check.”
“Certified nozzle?”
“Check.”
“Calibrated stopwatch?”
“Check. And don’t forget the blue roll,” Colin joked, holding up the ever-handy paper towels.

Calibration and verification were emphasized at every step to ensure precision. Even a slight deviation could lead to incorrect results, potentially allowing a faulty product to pass—or a perfectly good one to fail.

Our first task was to establish the water flow rate. According to the work instruction, the test required a flow rate of 100 liters per minute (L/min) with a tolerance of ±5%. Using a simple yet effective method, we connected the hose assembly to the mains water supply, filled a 50-liter bin and timed how long it took to reach the mark.

The result? 30 seconds, indicating a flow rate of exactly 100 L/min. We repeated the process three times to confirm consistency, a crucial step to ensure accuracy before beginning the test.

Conducting the IPX6 Test
Next, we positioned the test article—a small electronic device securely zip-tied to a stainless steel mesh frame. Following the standard, the nozzle with its 12.5mm diameter was placed at a distance of 3 meters, delivering a jet of water at high pressure.

The test required us to expose each face of the device to the water jet for 1 minute per square meter, ensuring every surface likely to encounter water in its real-world use was thoroughly tested.

“Always consider the product’s intended use,” Colin explained as he adjusted the setup. “Our role is to ensure the test reflects the product’s real-world conditions, as defined by the customer and the relevant standard.”

In this case, the client determined that testing the underside wasn’t necessary, as the product wouldn’t be exposed to water from below during its operational life. However, Colin pointed out that other standards, like ISO 20653 for automotive components, are more prescriptive. They require testing from all possible angles to account for dynamic conditions, such as water spray caused by driving through puddles, heavy rain, or off-road environments. These scenarios expose vehicle components—like undercarriage electronics, wiring and sensors—to water from multiple directions, including underneath, ensuring they can perform reliably even in harsh conditions.

Why Precision Matters
Throughout the process, Colin emphasised the importance of adhering to the specifications outlined in ISO 60529 and our lab’s ISO 17025 UKAS accreditation. Precision in setup, measurement and execution wasn’t just about passing the test—it was about ensuring the product could perform reliably and safely under real-world conditions.

A slight miscalculation in water pressure, flow rate, or duration could invalidate the results, leading to costly retesting or, worse, a failure in the field.

Lessons from the First Day
As the water jet arced through the air, I stood back, absorbing every detail. Until that moment, I’d never considered the depth of thought and precision required to ensure the safety and reliability of everyday products.

From calibration to execution, every step of the process was deliberate, each one critical to achieving a meaningful result. That day, I realised that environmental testing isn’t just about meeting standards—it’s about ensuring that products are ready to face the real world.

The lessons I learned on my first day stayed with me, shaping my approach to testing and the standards I hold myself to in every project.

Disclaimer:

This post reflects my personal experience and opinions from my time at TÜV SÜD and is not endorsed by or affiliated with TÜV SÜD in any official capacity. Any references to projects, processes, or colleagues are shared with respect for confidentiality and professionalism.