"Is it faulty when a fanless industrial PC feels hot to the touch?" In general, we're used to the slight warmth of a laptop or home PC, so when we touch the heatsink of a fanless industrial PC in operation, our immediate concern is whether it's overheating or malfunctioning.

In fact, the hot to touch heatsink does not mean it is malfunctioning but rather that the fanless industrial PC's passive thermal design is working. To operate stably for long periods in harsh environments, fanless industrial PCs have a completely different thermal philosophy than home PCs. Thermal design is the key to ensuring system reliability. This article will delve into why fanless industrial PCs "feel hot to the touch" and reveal the thermal management technologies behind them.

Fanless Industrial PC vs. Home PC: The Main Difference in Thermal Design Home PC: Active Cooling

• Uses fans to draw heat away from hot components like the CPU and GPU
• Pros: High cooling efficiency.
• Cons: Fans cannot operate in dusty, high-temperature, humid, or high-vibration industrial environments, as they may accumulate dust and result in damage or failure, leading to system overheating and shutdown.

Fanless Industrial PC: Fanless Passive Cooling

• Relies on thermal materials, aluminum enclosure, heatsink fins, and heat pipes to conduct heat to the surface for dissipation.
• Pros: Completely eliminates fans (point-of-failure), to offer high stability, maintenance-free, dust- and vibration-resistant, and extend lifespan.
• Cons: The surface temperature of the heatsink/ enclosure is higher and may feel "hot" to the touch.

Why Does a Passively Cooled Heatsink Get Hot?

In electronics, heat is the number one threat to component lifespan. High temperatures accelerate the aging of electronic parts, loosen solder joints, and even compromise data integrity.

The cooling principle employed by fanless industrial PCs is to conduct the heat generated by components to the outer surface of the heatsink/ enclosure, which the heat can then dissipate. Therefore, if a fanless industrial PC's heatsink/ enclosure is hot to the touch, it actually means it has effectively drawn heat away from critical components, ensuring system stability.

Three Common Passive Cooling Technologies in Fanless Industrial PCs

1. High-Efficiency Thermal Materials

• Industrial-grade thermal paste and thermal pads fill tiny gaps between the CPU/GPU and the heatsink.
• Long-lasting and resistant to degradation, they ensure stable cooling efficiency even under long-term high-temperature operation.

2. Aluminum Enclosure with Heatsink Fins

• The full aluminum enclosure itself acts as a large heatsink.
• Special fin structures increase the surface area to rapidly dissipate heat.

3. Heat Pipe Technology

• Used in high-performance or space-constrained models.
• Utilizes the principle of phase change to quickly transfer heat away from the heat source, significantly boosting cooling efficiency.

Neousys Technology's Fanless Thermal Design

In response to harsh industrial environments, Neousys fanless industrial PCs’ thermal design utilizes aluminum casing + heatsink fins + thermal materials. The layout is optimized at the mainboard design stage to evenly distribute hot components across the PCB to help achieve heat-soak equilibrium.

Based on test data, at an ambient temperature of 70°C, the aluminum heatsink can reached a maximum surface temperature of 88.8°C with infrared thermography showing uniform temperature distribution across the heatsink, suggesting the strategic placement of components effectively avoided heat-soaking in concentrated areas.

For installation within enclosures, Neousys' fanless flattop computers, FT series, their heatsink is mounted directly onto the enclosure wall surface with a thermal pad, conducting heat onto the outside of the enclosure. This design serves two purposes, one, it prevents heat buildup inside the enclosure, and two, without the heatsink fins, the system is smaller in dimensions, making it ideal for confined or enclosed systems.

Conclusion: Hot to the Touch Means Heat Conducted to Heatsink

When your fanless industrial PC feels hot, it means heat generated by components are being conducted onto the surface of the heatsink. It is protecting itself, ensuring stable long-term operations in harsh environments.

From advanced thermal interface materials and aluminum fins to heat pipe technology, these thermal designs are engineered to sustain fanless industrial PC high-performance and longevity of fanless industrial PCs, even under harsh environmental conditions.

• Learn more about Neousys Flattop Heatsink Fanless Computer: https://www.neousys-tech.com/en/product/product-lines/industrial-computers
• Learn more about Neousys Industrial Rugged Computer: https://www.neousys-tech.com/en/product/feature/flattop-heatsink-fanless-pc

Overview

The evolution of industrial Gigabit Ethernet cards combining Power over Ethernet (PoE) functionality has mimicked the growing demand for higher bandwidth, increased power delivery, and rugged reliability in modern industrial applications. Initially, 1Gb Ethernet PoE cards dominated the landscape, offering up to 15.4W per port under IEEE 802.3af (PoE) and later up to 30W per port with IEEE 802.3at (PoE+). These solutions served well for powering peripheral devices at the time, such as Gigabit IP cameras (requiring 3W to 5W), PoE-powered panel PCs, etc.

With the emergence of bandwidth-intensive applications, such as high-resolution video surveillance, AI-powered edge devices, and industrial automation, came the need for faster data rates and higher power delivery. This led to the development of 2.5Gb and 5Gb Ethernet PoE cards compliant with NBASE-T standards, maintaining backward compatibility with Cat5e cabling while improving throughput. These intermediate speeds enabled smoother data handling at the cost of generating excessive heat, but without the need to overhaul infrastructures. As a result, efficient thermal management has emerged as a critical consideration in the design and operation of high-speed Ethernet connectivity.

The integration of 10Gb Ethernet for ultra-fast data transfer and IEEE 802.3bt Type 4 (PoE++) for power delivery, offering up to 90W per port, represents a significant advancement in supporting modern edge AI applications and ultra-high-resolution cameras. This combination meets the bandwidth and power demands of next-generation devices.

Challenges of Deploying 10Gb PoE++ Cards in Embedded Systems, in the Field

When 10Gb PoE++ industrial add-on cards are installed into industrial embedded computers, they unlock powerful new capabilities for a range of high-performance edge applications, particularly in intelligent factory, smart city and public infrastructure deployments. These add-on cards provide both high-speed data transmission and robust power delivery over a single Ethernet cable, streamlining installation and reducing the need for separate power lines in remote or difficult-to-access areas. This makes them ideal for outdoor high-speed WiFi 7/ 6 access points, PTZ cameras, AI-powered PTZ precision cameras, smart light poles, and kiosk information stations. In these scenarios, reliable power and high-throughput data are critical. At the same time, these application deployments pose thermal management challenges during operation due to environmental conditions, and both fast data throughput and power delivery will result in excess heat generation. Therefore, most add-on cards rarely have both 10Gb and PoE++, and will only have one or the other advanced specification to minimize the heat generated, to sustain operations.

For example, AI-enabled PTZ cameras deployed in applications such as traffic monitoring or port security often demand up to 51 watts of power via PoE++ (IEEE 802.3bt) and require a sustained data throughput of at least 1 Gbps to enable real-time video streaming, object recognition, and AI inference at the edge. However, the high-performance demands of these cameras also result in elevated power and thermal loads. In harsh environment conditions, there have been instances of PTZ camera failures caused by overheating, where the PoE card was unable to maintain continuous power delivery or data throughput. Such thermal-induced incidents can lead not only to device shutdowns, but also data loss and packet drops, compromising both system reliability and real-time operations.

In addition to performance, the card's durability is also essential. Installed in embedded systems that are often deployed in exposed environments such as roadside, intersections, harbor ports, or public spaces, they must operate reliably in a wide range of environmental conditions. Therefore, PoE cards used in these embedded computers must be capable of withstanding wide range temperatures, especially for high data throughput and sustained power output operations.

Power-hungry devices such as pan-tilt-zoom (PTZ) cameras, 8K ultra-high-resolution cameras (typically requiring up to 50W), wireless access points, and embedded industrial PCs can all be supported through a single Ethernet cable. PoE++ simplifies installation with streamlined cabling and efficient power management—key advantages for high-density smart city deployments across roadsides, seaports, industrial zones, agriculture fields, and mining operations.

Neousys' Industrial Wide Temperature 10GbE PoE++ Card

Neousys Technology offers a robust range of industrial-grade PCIe add-on cards engineered to meet the stringent demands of harsh and mission-critical environments, including Gigabit, 2.5Gb and 10Gb cards with or without PoE. When released, the 10Gb high-speed Ethernet cards with advanced PoE++ IEEE 802.3bt, were one of the first 10Gb PoE++ cards specifically designed for industrial operations. The card enhanced system performance by enabling up to 10Gb of data throughput and up to 90W per port power delivery, crucial for smart city and intelligent factory applications such as machine vision, public safety monitoring, and industrial automation.

What sets the Neousys' 10Gb PoE++ card apart is its wide-temperature operation capability, withstanding extreme ambient temperatures ranging from -25°C to 70°C. Its strategic component placement design ensures continuous operation in extreme weather, from scorching summer heat to freezing winter temperatures, making it particularly suitable for deployment in outdoor applications such as roadside infrastructure, and remote industrial locations where environmental control is limited.

The 10Gb Ethernet interface can support multiple high-resolution data streams simultaneously or high-power devices such as outdoor WiFi 7 AP, ideal for real-time analytics, public safety monitoring, and large-scale sensor integration across smart city platforms. In addition, the ability to supply up to 90W per port to power devices also simplifies network deployment by reducing infrastructure complexity while lowering total cost of ownership.

Engineered for industrial computers and applications, the card incorporates rugged and highly-reliable components to ensure stable and consistent performance in demanding and thermal volatile environments. Its low-profile, plug-and-play PCIe Gen3 x4 interface enables seamless integration across a wide range of industrial PC systems, simplifying deployment complexity while reducing system downtime. The card supports GigE Vision 3.0 cameras with RDMA (Remote Direct Memory Access) technology, which significantly enhances data transfer efficiency by bypassing traditional CPU-intensive packet handling and memory copy operations. This results in up to 90% reduction in CPU utilization, allowing more resources to be dedicated to real-time processing tasks such as image analysis and AI inference. For industries requiring optimized performance, power distribution, and enhanced reliability in harsh environments, Neousys 10Gb PoE++ card is an ideal future-ready solution capable of sustaining high-throughput and low-latency connections for modern applications.

By integrating Neousys 10Gb PoE++ card into your embedded computer, it enables a compact yet highly capable solution for powering and networking intelligent devices in mission-critical indoor/ outdoor applications. Its combination of high-power output, fast data transmission, and industrial-grade reliability ensures your solution meets the rigorous demands of next-generation smart infrastructure.

• Learn more about Neousys Frame Grabber Cards:
  https://www.neousys-tech.com/en/product/feature/industrial-add-on/frame-grabber-card

In today's accelerating industrial landscape, the demand for higher CPU performance in industrial computers has reached unprecedented levels. As industries embrace digital transformation, edge computing, and AI-driven automation, processors with AI-capable performance have become indispensable.

Key Trends Driving the Need for High CPU Performance in Industrial Computers:

• AI and Machine Learning Integration
  Industrial applications increasingly rely on AI and machine learning (ML) for predictive maintenance, quality inspection, and process optimization. These tasks require processors with built-in AI acceleration, such as the AI NPU (Neural Processing Unit) featured in the Intel Core Ultra 200 series. By handling AI inference directly at the edge, these processors minimize latency and reduce reliance on cloud computing.
• Edge Computing Proliferation
  Edge computing is shifting data processing from centralized cloud servers to local devices. Industrial computers must now handle real-time processing of vast amounts of data generated by IoT sensors, cameras, and machines.
• High-Resolution Image and Video Processing
  From automated optical inspection (AOI) in manufacturing to facial recognition in security systems, industrial applications demand the processing of high-resolution images and videos. High-performance CPUs, with their advanced computing capabilities and support for high-speed interfaces like PCIe 5.0, seamlessly integrate with GPUs and frame grabbers, ensuring smooth handling of high-bandwidth image data.
• Increased Multitasking Requirements
  Modern industrial environments demand systems capable of running multiple applications simultaneously, such as data acquisition, machine control, and real-time analytics. Complex computing requires the CPU to be able to handle multiple tasks in real time and even support large-capacity memory so that they can operate simultaneously without affecting performance.

Challenges of High-Performance CPUs in Industrial Computers

• Thermal Management
  Higher CPU performance means increased heat generation during multitasking operations. Without effective thermal dissipation, excessive heat can negatively impact system stability, reliability, and even safety, ultimately reducing uptime.
• Power Design
  High-performance CPUs require greater power consumption. Coupled with the power demands of additional I/O devices, designing a stable power supply becomes a challenge. Industrial computers also need to accommodate wide-range DC inputs due to varying voltage stability in deployment environments.
• Harsh Operating Conditions
  The proliferation of edge computing has driven advanced applications to the edge, where industrial computers face challenging environmental conditions such as confined spaces, vibration, shock, humidity, and salt mist.

Learn more about Neousys' Rugged DNA and how we overcome these challenges to deliver durable, reliable, and fanless industrial computers.

• Why is Heat Dissipation Important to Industrial Computer Stability? (Learn More)
• What are Benefits of the Neousys Fanless Computer? (Learn More)
• Revolutionizing Fanless Computers in Confined Spaces (Learn More)

Conclusion

The rising complexity of industrial applications and the shift toward edge computing and AI underscores the need for high-performance CPUs in industrial computers. By adopting these advanced processors, industries can achieve greater efficiency, reliability, and scalability, paving the way for the smarter, more automated applications.

Industrial Computers Designed to Thrive in Industrial Environments

Compared to general-purpose computers, industrial computers have significant advantages in terms of durability, stability, and customization capabilities. Through rigorous testing and certification that meet international standards, industrial computers can meet the needs of diverse applications.

Neousys Technology focuses on the design of rugged embedded computers, providing high-quality products with wide temperature operation, vibration resistance, and international certifications such as EN50155, EN45545, and UL to accelerate project implementation while ensuring safety and reliability.

Conclusion

When facing extreme environments, choosing industrial computers with excellent durability is crucial. Through innovative technologies such as wide temperature, moisture-proof, shockproof, and dustproof, industrial computers can easily cope with challenges such as high temperature, humidity, salinity, and vibration to provide operation stability and efficiency.

Industrial Automation: Stability is Key!

For critical applications and year-round operations, the stability of equipment is crucial for improving production efficiency and reducing costs. However, traditional single-board computers or 4U embedded computers based on PCI Express, USB, and other interfaces often face challenges from environmental factors like temperature, dust and vibration. These issues lead to increased failure rates, decreased uptime, and hidden production costs.

Fanless Computers: The Ideal Partner for Automation

Fanless computers offer a new solution to these problems. Through advanced thermal design and high-quality components, they dissipate heat effectively without relying on fans, ensuring stable and reliable operation.

From the perspective of system integrators or end-users in factory automation, fanless computers offer several advantages:

1. Reliability and Durability

• Dust-Free Operation:
  Factory environments are filled with dust and particles that can damage fan-cooled systems by blocking airflow, causing wear, and eventually leading to system failures. Fanless designs avoid this, enhancing system stability.
  [Highlight] Neousys' waterproof fanless computers offer high-level dust and water protection, ensuring stable operation even in harsh environments with moisture or salt exposure. Want to know how fanless computers can benefit your factory? Click here for detailed specifications.
• Vibration Resistance:
  Industrial environments often involve vibration, which can loosen or damage fan components. Fanless designs eliminate this risk, making them more suitable for such conditions.
  [Highlight] Neousys' patented anti-vibration design ensures continuous, stable performance during AI inference or edge computing tasks, even with GPU cards installed. Click here to learn more about our design advantages.
• Extended Lifespan:
  With no moving parts, fanless computers have lower failure rates, extending the system's lifespan and reducing maintenance costs.

2. Efficient Thermal Management

• Passive Cooling:
  Fanless computers use passive cooling methods like heat sinks and heat pipes, efficiently dissipating heat. Combined with precise thermal design, these systems often match or even outperform traditional fan-cooled computers.
  [Highlight] Neousys' flat-top fanless computers deliver excellent cooling performance, even in enclosed spaces. Curious about how we achieve this? Click here for more information.

3. Environment Adaptability

• Wide Temperature Range:
  Fanless computers typically operate within a broad temperature range, making them suitable for extreme conditions such as high or low temperatures, ensuring stable operation.
• Wide DC Input with SuperCAP Protection:
  Accepting wide range 8V to 48V DC input, the system can be deployed in various industrial conditions. And with Neousys patented SuperCAP, it ensures the connected system is protected against electrical fluctuations, sudden loss of power, etc.

4. Lower Maintenance Costs

• High Reliability:
  No moving parts means fewer breakdowns.
• Reduced Maintenance Frequency:
  The fanless design eliminates the need for fan cleaning or replacement, cutting down on maintenance efforts and costs.
• Increased Uptime:
  Greater reliability means less downtime, boosting production efficiency.

5. Efficiency

• Space Efficiency:
  Without the need for airflow channels, fanless computers are more compact, thus saving installation space.
• Energy Efficiency:
  Without fans requiring additional power, overall power consumption is reduced.
  [Highlight] Neousys' compact POC series fanless computers meet the operational needs of tight spaces. Click here to explore more compact fanless computers.

6. Safety

• No Spark Risk:
  Fanless designs eliminate the risk of sparks from fan failures, improving system safety.

Conclusion

In automation applications, the reliability, durability, and environmental adaptability of fanless computers are making them an increasingly popular choice. While the initial investment may be slightly higher, the long-term benefits—higher reliability, lower maintenance costs, and increased productivity—make fanless computers a worthwhile investment for the future.

Propel AI Applications into Extreme Environments

Neousys waterproof computers is available in variants ranging from IP69K down to IP66 ratings. From rugged SEMIL series, boasting semi-military grade durability, to the AWP series with waterproof functionality, they are designed to excel in extreme environments. The computers feature powerful processing capabilities with advanced thermal management, and reinforced stainless steel design with M12 connectors to ensure uninterrupted operation in extreme temperatures ranging from -40°C to 70°C.

Neousys IP69K/ 67/ 66-rated Extreme-Rugged Waterproof Embedded & GPU Computers

Product Highlights

Robust Construction

Featuring corrosion-proof stainless steel and aluminum chassis, our computers are built air-tight to withstand moisture, salinity, and other environmental contaminants.

Powerful Processing

Powered by Intel® Core™ processors, NVIDIA® GPUs, and up to 64 GB DDR5 memory, the systems deliver exceptional computing power for demanding applications.

Rugged Connectivity

Equipped with a variety of M12 I/O ports including Ethernet, USB, and PoE+. The versatile connectivity options for seamless integration into industrial systems.

Total Cost of Ownership

The cost-effective IP66-rated waterproof systems are optimized to suit industrial computing needs and budgets without compromising on performance or reliability.

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IP69K-rated Extreme-rugged Computers

SEMIL-2000 Intel® 14th/ 13th/ 12th-Gen Core™ CPU 2U 19"/2 rack-mount form factor	SEMIL-2000GC NVIDIA® L4 GPU Intel® 14th/ 13th/ 12th-Gen Core™ CPU

IP67-rated Extreme-rugged Computers

SEMIL-1700 Intel® Xeon® E or 9th/ 8th-Gen Core™ CPU Patented SuperCAP-based power backup	SEMIL-1700GC NVIDIA® RTX A2000 GPU Intel® Xeon® E or 9th/ 8th-Gen Core™ CPU

IP66-rated Affordable Waterproof Computers

NRU-160-AWP NVIDIA® Jetson Orin™ NX/ Orin™ Nano 6x GMSL2 or 4x PoE+ GbE Ports	NRU-170-PPC NVIDIA® Jetson Orin™ NX/ Orin™ Nano 6x GMSL2 or 4x PoE+ GbE Ports	NRU-230V-AWP/ NRU-240S-AWP Powered by NVIDIA® Jetson AGX Orin™ SoM Support 8x GMSL2 automotive cameras via FAKRA Z connectors	Nuvo-9650AWP Intel® 13th/ 12th-Gen Core™ CPU 8V to 48V DC input with built-in ignition power control	POC-465AWP Intel® Atom® x6425E CPU 8V to 35V DC input with ignition power control

Applications

Military & Defense

The extreme-rugged design and GPU support, SEMIL series is ready for in-vehicle deployments to enhance unmanned vehicles’ operation capabilities, making them ideal for communication, ISR and UGV applications in battlefield.
(Learn more)

Mining/ Construction/ Forestry

Featuring shock/vibration resistant and ignition control, they are perfect for deploying on vehicles for remote monitoring and control systems operating at mining sites, construction zones, and forestry operations.
(Learn more)

Agriculture/ Husbandry

Its rugged stainless steel construction and optimized processing power aids precision agriculture and automation, such as autonomous tractor and livestock management.
(Learn more)

Seaport/ Maritime

The air-tight enclosure can withstand environment contaminants which allows for deployment in maritime environments such as for vessel monitoring, navigation, and communication systems.
(Learn more)

Food & Beverage

With AI computation, PoE+, and USB ports for cameras, the systems can provide uninterrupted operations in automated food processing and beverage production lines. The waterproof capabilities make them unfazed to environment contaminants.
(Learn more)

Oil & Energy/ Infrastructure

With rugged designs and the ability to meet C1D2 certification requirements, our systems are ideally suited for hazardous environments. They offer the durability and reliability needed to monitor system conditions without the risk of unexpected shutdowns, supporting effective predictive maintenance.