When integrating wireless modules into a product, modular approval simplifies the regulatory process by certifying the module in isolation. This can save time and effort for manufacturers. However, a common misconception is that modular approval eliminates the need for additional testing at the product level. While modular certification covers the module’s compliance independently, product-level testing ensures the final device operates safely and meets regulatory standards in its intended configuration.

If you’re curious about the differences between FCC modular and product-level certifications, check out our earlier blog: Modular vs. Product-Level FCC Certification. In this article, we’ll expand the discussion to include other global regulatory frameworks, such as CE and ISED, and explain why product-level testing is a necessary step.

What Is Modular Approval?

Modular approval is a regulatory process that certifies wireless modules, such as Wi-Fi or Bluetooth chips, for compliance with standards like FCC, CE, or ISED. This certification allows manufacturers to use these modules without needing to repeat certain tests, provided the module is integrated according to specific conditions, such as:

• Using the same antenna type and configuration.
• Ensuring the module operates within approved power levels.
• Maintaining shielding or housing design as originally tested.

While modular approval is invaluable for speeding up product development, it is not a complete solution. Once the module is embedded into a product, additional testing is required to account for factors introduced by the integration.

Why Product-Level Testing Is Still Necessary

1. Integration Challenges

When a module is integrated into a product, its performance can be affected by:

• Antenna Design and Placement: The positioning and type of antenna in the final product may change RF emissions and signal quality.
• Housing and Shielding: Enclosures can impact electromagnetic compatibility (EMC) and spurious emissions.
• Power Supply and Circuitry: Interactions with other components may introduce noise or alter performance.

Electromagnetic compatibility (EMC) ensures that the product does not emit excessive electromagnetic interference (EMI) or become susceptible to external interference. Modular approval certifies the module’s performance, but the complete product may behave differently due to:

• Noise from additional components, such as power supplies or processors.
• Insufficient shielding, which could amplify emissions.

Testing at the product level ensures the entire device complies with EMC standards like EN 301 489 and FCC Part 15B.

3. Verifying Transmitter Performance

Standards like EN 300 328 (2.4 GHz) and EN 301 893 (5 GHz) regulate spurious emissions and signal strength. Even with a certified module, integration can alter the module’s RF behavior due to:

• Proximity of components affecting signal patterns.
• Changes in the ground plane or antenna layout.

Product-level testing confirms the final device meets these requirements.

4. Electrical Safety

Safety standards such as EN 62368-1 require testing of the entire product to ensure it is safe for users. Modular approval does not cover potential hazards introduced by the product’s design, such as:

• Poor insulation leading to electric shocks.
• Overheating due to inadequate thermal management.

Regulatory bodies like the FCC, ISED, and CE mandate product-level testing to verify compliance for the entire device. Even with a certified module, testing ensures:

• The final product meets regional regulations.
• Variations in configuration or design do not introduce new compliance issues.

Key Standards That Require Product-Level Testing

Here are some key standards that necessitate product-level testing:

FCC and ISED Standards

• FCC 15.247 / RSS-247: For spurious emissions and power limits of devices operating in the 2.4 GHz and 5 GHz bands.
• FCC 15.407 / RSS-248: Regulates U-NII devices (e.g., Wi-Fi 6E) for the 5 GHz and 6 GHz bands.
• SAR Testing (RSS-102): Ensures RF exposure remains within safe limits.

CE Standards

• EN 300 328 / EN 301 893: Covers unwanted emissions and performance of 2.4 GHz and 5 GHz wireless devices.
• EN 62368-1: Safety standard for electronic equipment.
• EN 301 489-1/-17: EMC requirements for wireless communication devices.

The Consequences of Skipping Product-Level Testing

Ignoring product-level testing can lead to serious consequences, including:

• Regulatory Non-Compliance: Products may fail certification, delaying market entry.
• Product Recalls: Non-compliant devices already on the market may need to be withdrawn, resulting in lost revenue and damaged reputation.
• Fines and Penalties: Regulatory bodies can impose significant fines for non-compliance.
• Safety Risks: Undetected hazards can harm users and expose the company to liability.

Benefits of Product-Level Testing

Product-level testing ensures:

• Regulatory Compliance: Your product meets all global standards, allowing seamless market entry.
• Risk Mitigation: Identifies and resolves issues before the product reaches consumers.
• Customer Confidence: Demonstrates your commitment to safety and quality.

Conclusion

While modular approval provides a strong foundation for regulatory compliance, it is not the final step. Product-level testing is essential to account for integration challenges, ensure compliance, and safeguard your brand’s reputation. By investing in thorough testing, you’ll not only avoid costly delays but also deliver a product that meets the highest standards of safety and performance.

Need help navigating the certification process? Contact us to ensure your product is compliant and ready for market success!