03 July 2025

Charlie McRae, Systems Engineer at IDS-INDATA

Wi-Fi 7 has the potential to significantly enhance connectivity in industrial environments, offering ultra-low latency and high-speed wireless performance that supports a range of applications, from smart factories to AI-enhanced automation.

In practice, industrial deployments often encounter difficulties when existing infrastructure isn’t ready to meet the demands of Wi-Fi 7. Without careful planning and proper execution, businesses may experience downtime, suboptimal performance, and disappointing returns on their technology investments.

Below are three frequently encountered mistakes in deploying Wi-Fi 7 in industrial settings, along with practical ways to address them.

Mistake #1: Overlooking the importance of the wired infrastructure
Although Wi-Fi 7 offers significant performance improvements, its effectiveness depends heavily on the wired systems that support it. Many facilities still rely on legacy hardware, such as outdated switches or old Cat5 cabling, that can’t handle the throughput required for newer wireless standards. When this foundation is neglected, even state-of-the-art access points cannot operate efficiently. The result is a bottleneck that reduces the impact of what should be a significant technological upgrade.
Impact: Essential operations can suffer delays or interruptions, ultimately reducing the effectiveness of digital transformation investments.

Mistake #2: Failing to meet power needs in harsh industrial settings
Wi-Fi 7 access points designed for industrial use often require more power than previous models, typically using Power over Ethernet Plus (PoE++) or IEEE 802.3bt standards. However, many facilities lack the necessary switching equipment, or their environments make it challenging to maintain consistent power.
Challenge: Supporting ruggedised access points with higher power demands in demanding environments requires thorough planning, rather than relying on off-the-shelf solutions.

Mistake #3: Ignoring RF challenges and 6GHz spectrum planning

Industrial environments often include heavy machinery, metal structures, and thick walls — all of which can interfere with wireless signals. With Wi-Fi 7 utilising wider 320 MHz channels and the 6 GHz spectrum, RF complexity increases considerably.

Result: Poor RF design can lead to reliability issues and service disruptions that negatively impact business-critical processes.

Laying the right foundation

A well-planned deployment starts with solid physical infrastructure. That means upgrading to shielded Cat6A cables and deploying multi-gigabit switches capable of handling Wi-Fi 7’s throughput. Power delivery should be reviewed across the entire site, with PoE++-ready switchgear or industrial-grade injectors used where necessary.
To address environmental factors, Wi-Fi 7 access points should be rugged and rated for use in industrial spaces. Placement should follow detailed RF site surveys that consider interference, materials, and equipment layout.

Logical network design is also vital. Dividing networks to separate IT systems from operational technology (OT) traffic can preserve uptime and security. Regular monitoring, whether through managed services or in-house tools, helps ensure the network remains optimised over time.

Although WPA3 encryption is required for Wi-Fi 7 certification, relying on it alone to secure an industrial network can be a mistake. Many sites operate a mix of old and new devices, which can result in fallback configurations that compromise overall security.

New features, add functionality but also introduce new risks if not implemented securely. A lack of segmentation within the network can allow unauthorised access and lateral movement if a breach occurs. Without additional layers of protection, threats like rogue access points, device spoofing, or man-in-the-middle attacks remain possible, even in networks using WPA3.

Best practices

Security should be layered and proactive. Using certificate-based authentication (like EAP-TLS), enabling network access control (NAC), and applying Zero Trust principles can significantly enhance protection.

Separating IT and OT systems through microsegmentation can limit the impact of a breach. Wireless security reviews should be part of the same planning process as RF design to identify and eliminate vulnerabilities before deployment - a crucial step, and one not to be missed.

Wi-Fi 7 can revolutionise connectivity in industrial settings — but success depends on more than just installing new access points.