Extreme cold, heat and rapid temperature changes can affect batteries, cameras, sensors and other drone components during transport and storage. By considering the temperature profile, insulation materials and relevant MIL-STD requirements, packaging can be designed and tested accordingly. This helps protect sensitive drone components against cold, heat and rapid temperature fluctuations.
Summary of this article
Drone packaging should not only protect against impact, vibration and moisture. Temperature is just as important. During transport or storage, a drone, battery, camera, sensor or data link may be exposed to frost, heat or rapid temperature fluctuations. That is why, at Faes, we do not focus on one ‘correct’ temperature limit. Instead, we look at the complete usage profile of the packaging: transport, storage, deployment time, climate, humidity and the sensitivity of the components inside the case.
Extreme temperatures do not affect every component in the same way. Batteries, electronics, optical systems, adhesive joints and seals can all be sensitive to heat or cold. Ambient temperature only tells part of the story. For a proper design, we distinguish between ambient temperature, the temperature inside the case and the permitted storage and operating temperatures of the drone and its accessories.
A closed case placed in direct sunlight can become significantly hotter inside than the ambient temperature might suggest. Conversely, a case moved directly from a warm environment into a cold one can be exposed to condensation as warm, humid air cools down.
Temperature protection is therefore not just about insulation. It is about controlling heat transfer, moisture, condensation and the rate at which the temperature inside the packaging changes.
There is no universal temperature range that applies to every drone packaging solution. In practice, conditions can vary considerably. For example, storage or transport may take place at -20 °C or -30 °C, while a case can also be exposed to +40 °C, +50 °C or even higher temperatures. For specific military applications, even more extreme environmental conditions may form part of the requirement set.
These temperatures should not be seen as standard values that every drone case must meet. They are mainly useful for defining the actual usage profile. A drone transported for two hours at -20 °C requires a different solution from equipment stored for several days under the same conditions.
We therefore start with the specifications of the contents. We look at the permitted storage and operating temperatures of the drone and electronics, the charging, discharging and storage temperatures of batteries, and the minimum and maximum operating temperatures of cameras and sensors. The temperature behaviour of the case, foam and seals also matters.
For example, if a battery may be stored down to -20 °C according to the manufacturer but may only be charged above 0 °C, the packaging does not necessarily have to prevent the battery from ever dropping below 0 °C. What matters is understanding how quickly it cools down and how much time is required to bring it back within the permitted temperature range before use.
At low temperatures, the available capacity of many batteries decreases and some materials can become stiffer or more brittle. At high temperatures, electronics and batteries may age more quickly, while adhesives, foams and seals can lose some of their properties.
For us, the weakest component is therefore often decisive in the packaging design. It is not the case itself, but the most temperature-sensitive item inside it that determines how much thermal protection is required. In a drone kit, this may be the battery, but it could also be a camera, lens, measuring instrument or another electronic component.
We also take temperature fluctuations into account. A rapid transition from cold to warm can cause condensation on or inside equipment. That risk cannot be solved simply by adding a thicker layer of insulation. Sealing, moisture control and the way the case is opened also play a role.
There is no single insulation material that is automatically the best choice for every application. Foams are often used because they provide both mechanical protection and a certain degree of thermal resistance. However, we do not select a material based on insulation value alone. Density, moisture absorption, temperature behaviour, compression, chemical resistance, service life and impact protection are at least as important.
In some designs, a combination of materials is more effective than one thick layer of foam. This could include a load-bearing insert, a thermally insulating layer and additional measures against radiant heat or moisture.
More insulation is not automatically better. Insulation slows down both heating and cooling. If equipment needs to dissipate heat after use, a heavily insulated closed case can actually retain that heat for longer. We therefore always assess the complete thermal scenario.
MIL-STD-810 is frequently referenced in defence applications. It is important to understand that such a standard does not simply prescribe one mandatory temperature for every package. The standard describes test methods for various environmental stresses, including high and low temperatures, temperature fluctuations, humidity, vibration and shock. Which test conditions are relevant depends on the equipment, its usage profile and the requirements of the customer.
MIL-STD-810 therefore does not automatically mean that packaging has to operate from, for example, -40 °C to +70 °C. Such values may be relevant within a specific programme or test profile, but they are not universal requirements for every drone or packaging solution.
From our work for various suppliers to the defence sector, we know that it is therefore better not to start with the question: “Is this case MIL-STD compliant?” A better question is: what specific loads must the complete packaged configuration be demonstrably capable of withstanding?
We look at the combination of case, interior and contents. A rugged outer case alone does not guarantee that a drone, battery or sensor will withstand the required temperature exposure.
A good thermal packaging design starts with requirements, not with material selection. We first identify the critical components, temperature limits, transport duration, storage duration, climatic conditions and the required level of deployment readiness.
We then determine which measures are necessary. This may include insulation, but also alternative component positioning, greater distance from the outer wall, moisture control, different sealing or controlled conditioning before use.
For critical applications, we recommend validating the design with temperature measurements. By placing sensors at relevant locations inside the case, we can see how quickly the contents actually heat up or cool down. This allows us to base design decisions on measurement data rather than assumptions.
Test the complete configuration: case, interior and contents. Measure both the ambient temperature and the temperature at critical locations inside the packaging. Define the acceptable limit values and exposure duration in advance.
Allow the equipment to acclimatise in a controlled manner where necessary before switching it on. Pay particular attention to condensation when cold equipment is brought into a warm, humid environment. Always follow the temperature and operating instructions provided by the drone and battery manufacturers.
You can, but standard foam is not automatically suitable for every application. The material selection must suit both the mechanical and thermal loads, as well as factors such as moisture, chemical exposure and service life.
This cannot be determined from insulation thickness alone. The initial temperature, ambient temperature, exposure duration, mass of the contents, internal heat sources and construction of the case all influence how quickly the internal temperature changes.
The specifications of the drone and its individual sensitive components are the starting point. We then translate the expected transport and storage conditions into packaging requirements. This creates a substantiated temperature profile that actually matches the application.
Michel Prins is Account Manager at Faes and a specialist in Safety & Security. Thanks to his background at the Ministry of Defense and years of experience in the sector, he advises organizations on reliable packaging solutions for critical applications. He combines practical knowledge with technical expertise to package sensitive equipment safely and efficiently.
More articles by Michel PrinsGood packaging doesn’t just happen by chance. Using a tried-and-tested approach, our specialists guide you step by step from the initial idea to the finished product.
