Industry Solutions
Battery & EV leak testing verifies the sealed components that protect energy storage, cooling and high-voltage systems in production.
Battery and EV manufacturing uses leak testing to evaluate battery pack enclosures and trays, cooling plates and coolant loops, cell and module housings, connectors and sensors, charging components, and high-voltage electronics housings.
The appropriate method depends on the component, its internal volume, the manufacturer’s acceptance target and the production station. Zaxis supports both peer leak-testing lines: air methods for production testing and trace-gas methods when a lower leak-rate requirement calls for a measurable tracer.
Request for QuoteRequest a DemoBattery and EV assemblies combine sealed energy storage, cooling and high-voltage components. A production test must address the specific component rather than treating the complete vehicle as one test volume.
Battery pack enclosures and trays, cooling plates and coolant loops, cell and module housings, connectors and sensors, charging components, and high-voltage electronics housings each need a method and fixture appropriate to their purpose.
Methods used
Air leak testing and trace-gas leak testing are peer options. The test plan starts with the manufacturer’s target and the component’s fluid, volume and production requirements.
Pressure decay pressurizes a sealed component, isolates the air source, then measures pressure loss over a defined interval. Vacuum decay evacuates a sealed part and measures movement back toward atmospheric pressure.
Both non-destructive air methods can support repeatable production decisions when the part, fixture, settle time and reject target are defined.
Compare pressure and vacuum decay →Mass flow measures air moving through a connected component against programmed minimum and maximum flow values. It is a useful option when the product has an intentional flow path or when flow-based testing suits a larger-volume component.
Read about mass-flow testing →A trace-gas test fills a sealed part with a gas the detector can measure, then measures the escaping tracer. Helium, hydrogen forming gas and argon selection follows the reject limit, production environment and detection method.
Z-Charge prepares a part and can coordinate gross leak, pressure-decay and vacuum-decay checks before Z-Ion performs helium detection.
Explore trace-gas testing →The table is a starting point for application engineering, not a universal specification. Final method, fixture and acceptance target are set for the manufacturer’s part and validation plan.
| Component | Recommended method | Why | Zaxis product |
|---|---|---|---|
| Battery pack enclosure, tray or high-voltage housing | Pressure decay or vacuum decay; mass flow for large volumes | Sealed enclosure testing can use a controlled pressure or vacuum cycle; larger internal volumes need appropriate stabilization time. | Z8, Z5, Z5L, Z1 or Z8N air leak testers |
| Cooling plate and coolant loop | Pressure decay, vacuum decay or mass flow | A connected fluid path can be evaluated with a repeatable air-based pressure, vacuum or flow test selected around the circuit and target. | Z8, Z5, Z5L, Z1 or Z8N air leak testers |
| Cell or module housing | Vacuum decay; trace gas helium or hydrogen for very low leak rates | A sealed housing may suit a non-destructive vacuum cycle; trace gas provides a measurable tracer where the required leak target is lower. | Z5L or Z-Charge + Z-Ion |
| Connector, sensor, charging component or compact electronics housing | Pressure decay or vacuum decay; trace gas for very low leak rates | The part’s sealing access and required leak target determine whether an air cycle or tracer-gas measurement is appropriate. | Z1, Z5, Z8N or Z-Charge + Z-Ion |
Select an air tester around port count, test pressure, fixture and automation needs; use the Z-Charge + Z-Ion system when a coordinated helium process fits the required detection method.
Z8Modular air leak tester with up to four test ports for sequential or concurrent production testing.
Z5Compact multi-channel air tester for configured factory stations.
Z1Single-channel air tester built for machine integration and cascading test cells.
Z-Charge + Z-IonCoordinated part preparation and helium leak detection in one trace-gas test cell.SAE J3277/1, Liquid Leak-Tightness Standards for Propulsion Battery Packs Recommended Practice, describes nondestructive in-line production testing correlated to IPX7-class ingress for propulsion battery packs. IEC 60529 is the standard associated with IP codes, including IP67 and IPX7 context.
These references explain scope; they do not make a production tester certified to or compliant with a standard. Acceptance criteria are set by the manufacturer’s validation. Zaxis helps correlate production air tests to those criteria through the application, fixture and programmed test sequence.
IP67 and IPX7 describe ingress-protection context, while an in-line pneumatic test is a controlled manufacturing measurement. The manufacturer must define the relationship between its product-level validation, production target and acceptance decision.
Battery packs and trays can have large internal volumes, so the fixture, added test volume and stabilization time should be considered together. A large-volume enclosure needs a repeatable sequence that allows the measurement to settle before the decision is made.
A custom leak-test fixture can seal large enclosures, close multiple openings and present a clean connection to the tester. Multi-port testing can isolate or test more than one location when the part and production process require it.
For automated lines, Zaxis connectivity options include 24 VDC I/O, Ethernet TCP/IP, EtherNet/IP, RS232, RS485 and USB on compatible platforms. The station can use programmed results and line communication for PLC integration and production traceability.
Leak testing protects sealed battery and EV assemblies; precision dispensing addresses a separate battery-production need. Zaxis eVmP metering pumps are used for controlled dosing of battery-production fluids, including electrolyte and thermal-interface materials where the manufacturing process calls for repeatable volume control.
Read the battery-production metering-pump overview and the electrolyte battery dosing project to see the production context for eVmP configurations. These dispensing applications are distinct from air and trace-gas leak testing, but can be planned alongside battery-line automation.
Test plans can evaluate sealed pack enclosures and trays before they continue through assembly, using a fixture and air method selected for the volume and target.
Cooling plates and coolant loops can use a configured pressure, vacuum or flow approach around the circuit, connection and production requirement.
Connectors, sensors, charging components and high-voltage electronics housings can be evaluated with an air or trace-gas method chosen around access, sealing and target leak rate.
Battery and EV leak testing evaluates sealed battery pack enclosures and trays, cooling plates and coolant loops, cell and module housings, connectors and sensors, charging components, and high-voltage electronics housings during manufacturing.
Pressure decay or vacuum decay can be used for a sealed battery pack enclosure. For a large internal volume, stabilization time and fixture volume are important; mass flow can also be considered where a flow-based approach suits the component.
SAE J3277/1 is a recommended practice for liquid leak-tightness of propulsion battery packs and describes nondestructive in-line production testing correlated to IPX7-class ingress. IEC 60529 provides IP-code context. Your validation team sets the acceptance criteria; Zaxis helps correlate production air or trace-gas tests to those criteria. Standards define requirements for the product under test, not certification of the test equipment.
Trace gas can be considered when the required leak target is lower than the air-based method can support or when a measurable tracer and the selected detection method fit the application. Zaxis offers helium, hydrogen and argon trace-gas guidance plus Z-Charge and Z-Ion systems.
A fixture seals the part, controls added test volume and provides repeatable connections. For battery enclosures or multi-port parts, it can close multiple openings and support a defined automated sequence.
Compatible Zaxis platforms provide connectivity options including 24 VDC I/O, Ethernet TCP/IP, EtherNet/IP, RS232, RS485 and USB. The required interface and traceability approach should be confirmed for the specific platform and line.
