6 Misconceptions That Could Cost You a Launch
Our appetite for technology that moves with us—on our wrists, over our eyes, on our chests—increases every year. Given their small stature, these wearable devices tend to be low voltage. That means they should carry low risk, right? Not quite. Product safety is more crucial than ever when users are up close and personal with their devices for hours or full workdays at a time. Our team at Product Safety Consulting has been certifying wearables since their inception. We’ve watched these devices transform from clunky and cumbersome to sleek and super powered. But increased capabilities have only upped the ante for spotting hazards early. Let’s dive into the most common (and costly) assumptions we see manufacturers make and separate what flies from what gets flagged.It’s Low Voltage. It Can’t Shock Anyone.”
Myth: Low voltage = low risk
Reality: Even low voltages can create shock hazards, especially with exposed metal, charging contacts, or skin contact over extended periods of use.
Wearables sit directly on the skin, in the mix with sweat, moisture, and movement. That makes fault protection and isolation testing just as critical as it is for larger devices.
What we test: Touch current, insulation breakdown, charging circuitry
Our role: We identify areas where insulation or layout isn’t up to code. Why? To help you fix it fast.
“We Already Made It Waterproof. It’ll Slide.”
Myth: IP68 = job done
Reality: Waterproof ≠ safe. In fact, sealing in heat or isolating power poorly under wet conditions is a common failure point.
IEC 62368-1 isn’t just about water ingress. It pays close attention to whether or not your waterproof design creates secondary risks, like trapping heat or letting conductive materials corrode near users.
What we test: Thermal rise under fault conditions, corrosion, short-circuit behavior in wet environments
Our role: We pressure-test enclosures, simulate sweat, and catch these issues ASAP.
“It’s Just a Fitness Tracker. No Sweat”
Myth: Simpler devices don’t need certification
Reality: If it has a battery, wireless radio, or charging port, it needs to meet IEC 62368-1. Period.
We’ve certified everything from heart rate rings to posture monitors. Basic devices are often the ones that skip formal safety design, and end up failing late in the game.
What we test: Charging systems, battery thermal behavior, low-voltage safety
Our role: We help you build certification into your product, not bolt it on later.
“A Little Battery Never Hurt Anybody.”
Myth: Tiny battery = tiny risk
Reality: Small lithium cells can still overheat, leak, or catch fire, especially under stress. Wireless charging? Even riskier without proper thermal control.
We’ve seen all the hypotheticals come to life: swelling batteries, runaway charging, and magnetic connectors that get hot enough to leave their mark.
What we test: Battery protection circuits, wireless charge temperature rise, drop/fault behavior
Our role: We model your worst-case scenarios and help you prevent them, before they end up all over social media.
“Our Product Passed EMC Testing. It’s Good to Go!”
Myth: EMC compliance = 360 safety
Reality: EMC is just one slice of the safety pie. Thermal, shock, optical, and mechanical risks are not covered in a basic emissions test.
Plus, different wireless systems (Bluetooth, WiFi, GPS) can interact in unpredictable ways. This is especially true when a device is worn tightly on the body.
What we test: RF safety, antenna placement, unintended emissions, interference with safety systems
Our role: We run full-scope testing in a single plan, so nothing falls through the cracks.
“We Can Worry About Safety After Beta.”
Myth: Certification comes after the fun part
Reality: Most wearables that fail testing do so because of design decisions made early (i.e., connector placement, board layout, or battery choice).
Waiting until post-beta for a safety review means higher costs, longer delays, and rushed redesigns.
What we offer: Design reviews, pre-compliance risk analysis, thermal simulations
Our role: We help teams build safely from the start, instead of scrambling to retrofit safety systems.
Don’t Let Myths Become Dangerous & Expensive Mistakes
Wearable certification often comes with a dose of reality that’s best administered early. The most important thing to keep in mind when it comes to your wearable brainchild? No matter how tiny, low voltage, or seemingly harmless, the risks are real.
And in a category that touches the body, even a minor safety issue can damage your reputation or delay your launch.
Want to know what your design might be missing?
Let’s review it together. Contact Product Safety Consulting at 877-804-3066 or [email protected] for a quick pre-compliance consultation. We’ll flag potential issues before they become expensive ones and help you get certified smarter, faster, and safer.