Ocean-Grade LPWAN IoT for Floating Telemetry

Case Study • LPWAN AND Marine-Grade Enclosure

Ocean‑Grade LPWAN IoT for Floating Telemetry

LoRaWAN electronics, PCB development, and Carbon‑Kevlar composite enclosures for harsh marine environments (IP67‑ready).

Project Type: Research & Development Focus: LPWAN + PCB + Enclosure + Integration Final LPWAN: LoRaWAN Enclosure Target: IP67‑ready Outcome: Commercial scale‑up pathway established

Executive Summary

AQRESS executed a research and development programme to design and validate an ocean-capable, low-power IoT telemetry system that can float in harsh marine conditions while transmitting multiple data types to a central control room. The engagement covered LPWAN technology evaluation, end-to-end system design, electronics/PCB development, enclosure engineering, and full integration testing with a clear pathway for commercialisation and scale. The resulting solution selected LoRaWAN as the final Low Power Wide Area Network (LPWAN) technology and implemented a hybrid carbon‑Kevlar composite enclosure designed to support high durability and water ingress protection aligned to IP67 requirements. The project demonstrates AQRESS’ capability across IoT R&D, embedded electronics, LPWAN deployment design, 3D printing prototyping, composite material selection, and manufacturing readiness, capabilities applicable to mining, agriculture, asset tracking, maritime, fisheries, and environmental management.

Project Drivers & Requirements

The client required a robust, low-power system that could:

Operate in harsh ocean conditionsSaltwater exposure, UV, impact, and corrosion risk.
Float while protecting electronicsMaintain buoyancy and protect sensitive circuitry.
Transmit multiple data typesSend various data types back to a central control room.

Our Approach

1) LPWAN Technology Investigation

AQRESS investigated the best Low Power WAN technologies suited to the selected environment, focusing on:

  • Coverage characteristics
  • Power consumption profile
  • Reliability and network architecture options
  • Suitability for remote telemetry deployments

Outcome: Selection of LoRaWAN as the final implemented technology.

2) LPWAN System Design & PCB Development

AQRESS designed the full LPWAN electronic system, including:

  • Final PCB set design
  • Building the electronic circuit
  • Testing performance in conditions representative of ocean deployment

This workstream ensured the electronic design was aligned to power, reliability, and telemetry requirements.

3) Floating Enclosure Engineering (Prototyping to Composite)

AQRESS engineered a floating enclosure capable of protecting the LoRa circuitry while operating in the ocean. This included researching materials suitable for seawater limitations and harsh environments and iterative prototyping using 3D printing with:

  • PLA
  • ABS
  • ASA
  • Carbon fibre filaments

Final material selection: Composite material, specifically a hybrid carbon‑Kevlar composite for final manufacturing.

Why Hybrid Carbon‑Kevlar Composite (IP67‑Ready) vs PLA Prototypes

Strength & impact resistanceBetter survivability against wave impact, handling, and accidental drops than typical PLA prototypes.
Fatigue performanceImproved durability under cyclic loading in marine conditions.
Harsh-environment durabilityBetter long-term performance under UV exposure and saltwater conditions than PLA used for prototyping.
Sealing integrity for IP67 targetsHigher rigidity supports reliable gasket compression and sealing interfaces to help meet IP67 ingress protection goals.
Toughness (reduced brittle failure)Kevlar reinforcement improves toughness where brittle cracks could compromise waterproofing.
Prototype → production pathwayPLA/ABS/ASA are ideal for rapid iteration; composites are better suited for long-term ocean deployment.

System Integration, End‑to‑End Testing & Scale‑Up Planning

AQRESS integrated the electronics, communications, enclosure, and software pipeline into a complete system and completed end-to-end testing. The programme also included planning and preparation for scaling the solution toward commercialisation.

Team Mobilised

AQRESS delivered the solution using a focused multidisciplinary team comprising of:

Electronic Engineers Project Manager Software Developers

Outcomes & Capability Demonstration

LPWAN technology evaluation & selectionInvestigated best-fit LPWAN options for the selected environment and implemented LoRaWAN.
Embedded electronics & PCB developmentDesigned the LPWAN system with a final PCB set, built the electronic circuit, and tested in an ocean environment context.
Marine enclosure engineeringDesigned a floating enclosure to protect LoRa circuitry while operating in harsh ocean conditions.
Rapid prototypingIterative prototyping using 3D printing with PLA, ABS, ASA, and carbon fibre filaments.
Composite material selectionSelected a hybrid carbon‑Kevlar composite for final enclosure manufacturing aligned to IP67-ready targets.
System integration & scale-upIntegrated the entire system, completed end-to-end testing, and prepared the solution for commercialisation.

Applications Across Industries

The same technology foundations can be adapted for multiple sectors requiring low-power remote telemetry and robust enclosures:

Maritime / FisheriesFloating monitoring nodes, equipment telemetry, environmental sensing.
Environmental ManagementWater and coastal monitoring, conservation data capture, remote telemetry.
AgricultureRemote field sensing, irrigation telemetry, asset monitoring in low-infrastructure areas.
MiningRemote asset tracking, environmental compliance sensing, instrumentation support in rugged sites.
Asset Tracking & LogisticsLong-range low-power tracking where cellular coverage is limited or cost-prohibitive.
Maritime OperationsTelemetry and monitoring for marine assets requiring durable, sealed enclosures.

Why Partner with AQRESS

End-to-end IoT deliveryHardware, firmware/software, connectivity design, and system integration delivered as one programme.
Harsh-environment engineeringReal-world design considerations for marine exposure, sealing integrity, and durability.
Manufacturing readinessPrototyping to composite material selection and production pathway planning.
Multidisciplinary teamsElectronic Engineers, Software Developers, and Project Management working in one delivery model.
Scalability focusDesigned for scale, supporting commercial rollout beyond prototype demonstrations.
Cross-industry applicabilityLoRaWAN-based telemetry adaptable to mines, agriculture, maritime and more.

From Prototype to Commercialisation

This implementation demonstrates our ability to progress from LPWAN technology evaluation to proven electronics, enclosure engineering, full system integration, and a scale-up pathway; delivering solutions that are designed to be tested, proven, and commercialised for real-world deployments.

Next Steps

If your organisation needs an LPWAN-enabled system for harsh environments such as marine, mining, agriculture, or remote asset telemetry; AQRESS can support feasibility, design, prototyping, testing, and commercial scale-up.

Let's Engage