How Automated Leak Testing for Manufacturing Increases Efficiency

How Automated Leak Testing for Manufacturing Increases Efficiency

Leak testing is an essential step in any manufacturing process. It ensures your products meet guidelines set by the FDA, USDA, OSHA, FMCSA, and other regulatory bodies applicable to your industry. Leak testing also guarantees no problems have occurred during manufacturing and allows you to mitigate risk while delivering high-quality components.

Traditional leak tests involve submerging a component in water and visually checking for bubbles. However, according to Sandia National Laboratories, nearly 30% of leaks are missed when the results depend on a human inspector. Automated air leak testing for manufacturing systems can remove this risk. They enhance your OEM manufacturing process by collecting and analyzing data, streamlining repeatable testing to ensure quality, and eliminating the chance of human error.

The Problems with Traditional Water Dunk Testing Processes

Water dunking, also called bubble testing, remains the oldest leak test technique. Still used in manufacturing lines across sectors, water dunking is often inefficient as it takes a long time to complete, features low sensitivity, and requires an operator to visually identify leaks. Other challenges include:

  • Difficult to maintain consistent conditions
  • Water is easily contaminated
  • Viscous materials can mask leaks during testing
  • Time is lost due to long test times, cleaning, and drying a part after testing
  • Large water tanks use up valuable space on production floors

Automated Air Leak Testing During Manufacturing Processes Creates More Efficient Systems

Automated air leak testing used during manufacturing processes will enhance your system’s overall efficiency while improving the quality of your final products. Air leak testing is non-destructive as it uses dry air to check for defects and has a smaller physical footprint. Various types of automated air leak testing for manufacturing are available to match your specifications, such as:

If you need help determining which automated air leak testing system is best for your OEM production, contact Zaxis today. We’ll work with you to navigate your options and find the right solution for your processes.

Automated Leak Testing Saves Time & Money

Automating air leak testing during manufacturing saves you time, money, and labor hours. The leak tester will notify line operators if suboptimal conditions occur, making it easy for floor workers to quickly address issues, malfunctions, or problems. Product defects are identified faster, minimizing turnaround time. As less employee oversight is required, your manufacturing team is freed up to address higher-order concerns in your facility.

Accurate & Repeatable Methods for Precision Manufacturing

Compared to more traditional water dunking test methods, automated air leak testing delivers precision results with a higher degree of accuracy and repeatability. Reliable automated testers made by a trusted manufacturer—such as Zaxis, Inc—are designed to improve over time as more data is collected. Fewer defective products leave your facility as you refine, enhance, and create a more efficient manufacturing process using automated leak testing methods.

Scalable Automated Leak Testing Systems Fit Your Specifications

Digital leak testing systems used during manufacturing processes allow you to scale production and increase the speed of quality assurance testing. Multiple types of leak testers are available to match your needs, and automated leak testing systems are configurable to meet most specifications.

Call 801-264-1000 to speak with an automated air leak testing expert and find the best equipment for your manufacturing facility.

Automated Leak Testing Methods for Manufacturing in Any Industry

As manufacturing methods become more automated, advanced, and digitized, all aspects of your production must keep pace. Automated leak testing used during the manufacturing process is an excellent way to certify product quality while keeping up with demand. Automated leak testing maximizes efficiency across industries but is particularly useful in manufacturing:

Contact Zaxis to Order Automated Leak Testing Systems for Your OEM Outfit

Zaxis Inc is a leading USA-owned and operated automated leak testing system manufacturer. Our leak testers are explicitly designed for OEM assembly and manufacturing lines. We’ve engineered our products to support you as you build quality products that meet stringent regulations to satisfy your customers. Your success is our success, and we are ready to help you navigate our automated leak testing systems to find the best solution for your facility.

Contact us or request a quote today to get started. We’ll be in touch as soon as possible to discuss the right option for your manufacturing goals.

Common Air Leak Testing Methods

Common Air Leak Testing Methods

Figuring out which leak testing system is best for your manufacturing or assembly operation can be a challenge. Air leak testing for electronics, medical devices, automotive components, and more all have their own unique set of standards, regulations, and guidelines that must be met. Before investing in new non-destructive testing equipment for air leak detection, be sure that you are selecting the best standard type of air leak testing method for your industry, facility, and production.

Pressure & Vacuum Decay Leak Testing Methods

Pressure decay leak testing is commonly applied in manufacturing operations involving sealed components with an access port, such as catheters, implantable devices, and sensors or indicators. After the leak tester fills the component with pressurized air, the valve is closed to allow the pressure to reach equilibrium. If the air pressure decreases, then a leak is present and your component is rejected.

Vacuum decay air leak testing is the opposite of pressure decay. Instead of filling a component with air, the air is completely evacuated. If the pressure rises during testing, then a leak is present in your part. This type of leak testing method is commonly applied to locate leaks caused by external sources. It is also an ideal solution for automotive fuel injectors, medical catheters, and more.

Mass Flow Air Leak Detection

As the name implies, mass flow air leak detection equipment measures the amount of air that flows through a component or part. Mass flow testing can be used to test both small and large volume parts. For small parts, the extremely small internal volume allows for very low test times, generating a high throughput of production. In large parts, the flow rate can be adjusted to maximize the speed of the test. Standard applications for mass flow air leak testers include:

  • Catheters
  • IV sets
  • Check valves
  • Tubing
  • Metering devices
  • And more!

Occlusion Methods

If blockages are a concern for your manufacturing production, then occlusion testing is one of your best options. Your product is filled with regulated air. All valves close after your preset pressure is reached. The downstream port is opened so you can measure the pressure loss. A lack of decay denotes an issue, and further steps must be taken. Occlusion non-destructive methods are standard when testing catheters, check valves, tubing, and similar parts.

Burst Pressure Leak Test

Burst pressure tests measure the maximum pressure your component can withstand before catastrophically failing, or, as denoted by the name, “bursting.” Your part is attached to the test port and pressurized. After pressure sensors measure the pressure ramp rate and burst event, you compare your test results to your pre-established parameters. Design engineers favor burst pressure leak tests as they help establish the best material for a part, component geometry, and more.

Note: Burst pressure tests are a type of destructive testing. However, for check valves and similar components, it can be run as a non-destructive test.

Pressure Cracking Air Leak Detection

Often compared to burst pressure tests, pressure cracking air leak tests detect leaks such as a valve opening. Using two ports, you set specifications for minimum and maximum pressures required to open your device. Crack tests then measure the success or failure of your part by measuring increases and decreases in pressure. They are often applied to industrial components with a small amount of weep (or leak) before the full opening, including check valves and needleless injection sites.

Chamber Air Leak Test

Applied to find air leaks in sealed packing or devices without an opening, chamber air leak tests are implemented by placing your product inside a sealed chamber. That chamber is pressurized. Any pressure drop signifies that your product has an air leak. Chamber air leak tests are non-destructive and used throughout a variety of industries, including for testing:

  • Medical implantable devices
  • Electronic enclosures
  • Sensors and indicators
  • Radios, cell phones, watches, and other consumer goods
  • And many other components!

The Best USA-Made Air Leak Detection Equipment

Deciding which standard type of leak detection system is best for your production can be difficult, but Zaxis, Inc. is here to help. Since we first opened our doors, we have been dedicated to providing the best non-destructive air leak detection equipment for industrial manufacturers. Our air leak testing systems for electronics, medical devices, and other sectors are second to none, and we work hard to find the best solution for your unique production needs.

Ready to learn more about Zaxis and how we can support your manufacturing application through the market’s finest air leak testing for electronics and other devices? Contact us or call 801-264-1000 today. Our experts will be in touch as soon as possible.