Leak Testing in Manufacturing – Live Discussion

Leak Testing in Manufacturing – Live Discussion

Leak Testing in Manufacturing – Live Discussion

Leak Testers

The modular design of Zaxis leak testers enables us to meet the demands of a wide variety of applications.

Volumetric Leak Testing for Balloon Catheters

Balloon catheters and multi-lumen catheters are used throughout the medical industry. From administering essential intravenous medications to performing surgeries, catheters have no room for error, leaks, or compromised performance. When manufacturing balloon...

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...

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...

Leak Testing Critical in EV Manufacturing

Batteries are the most costly and complex part of EV manufacturing. To assure performance and product safety, batteries are leak tested throughout the manufacturing process to meet strenuous specifications.

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Pressure and Vacuum in one iKit Leak Tester

Pressure and Vacuum in one iKit Leak Tester

Pressure and Vacuum in one iKit Leak Tester


A slim, compact design that saves on valuable manufacturing space. Easy to concatenate together for automation.

Zaxis Leak Tester in Action

Watch Zaxis Leak Tester Now https://vimeo.com/581246944 Zaxis Leak Tester integrated into a customer robotic application See how one customer integrated a Zaxis leak tester into a robotic application? Zaxis leak testers are configurable, accurate and repeatable....

Quality Leak Testing in Medical Manufacturing

Quality Leak Testing in Medical EquipmentLeak testing medical devices is crucial to any medical equipment manufacturing operation. Zaxis is here to help. Our experts discuss medical devices that benefit from leak testing, outline our leak testers for medical...

Covid 19 Response Thank You from Air Logic

In response to Covid 19 many companies had to react and adapt quickly. Air Logic sent our employees this wonderful thank you video.

The Ideal Gas Law & Leak Testing Video

During leak testing, changes in pressure can occur due to changes in temperature, volume, and number of moles of the gas.

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Pressure Decay Leak Testing in Automation

Pressure Decay Leak Testing in Automation

Pressure Decay Leak Testing in Automation

In automated manufacturing many assembled products require leak testing to validate product viability and quality. A leak test is used to determine if an assembled object, product, or system functions within a specified leak limit. Leaks occur when gas or liquid flow through an object via an imperfection or manufacturing defect such as holes, cracks, weak seals, etc.

The automation of leak testing generates several key challenges, such as real estate on a production line, strict quality standards, efficient productivity, as well as communication and data sharing with the rest of the automation equipment.

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Proximity is Key

Square footage on a production line is valuable and costly. Leak testers are often integrated into assembly lines however they best fit. Many standard pressure decay leak testers measure over 12” wide. A common solution for integration is to extend the connection hoses between the part under test and the leak tester which can be several feet away. The longer the connection tubing, the more volume is used in a leak test, which can have a devastating effect on productivity as well as the accuracy of leak tests.

The volume of air used in a leak test includes the internal volume of the tester, the volume contained in all of the connection tubing, as well as the volume of the product under test. The farther a leak tester is from the part under test the larger the test volume. The larger the volume the longer the volume takes to pressurize which negatively effects productivity and throughput.

A higher test volume can also impede the leak testers ability to detect a leak. Think of this in terms of tires. You have a car tire which holds a large volume and a bike tire which holds a small volume. If both tires run over the same nail, what happens? The bike tire flattens almost immediately while the car tire slowly loses air over time. The smaller the test volume the faster and easier it is to detect a leak. The larger the test volume the longer it takes to identify if there is a leak, meaning extended test times with a lower accuracy of detection.

In terms of instrumentation, when running a pressure decay test, the value attributed to the pressure decay is the digital signal from the pressure sensor. When testing objects with the same size hole, such as a bike and car tire, the object with the larger test volume (car tire) will translate into a smaller signal than an object with a smaller test volume (bike tire). The pressure decay value is directly proportional to volume. Smaller signals require more time to detect a leak. Electrical, pneumatic, thermal or atmospheric effects, or noise, can mask small signals as well as influence the pressure decay value which has a negative impact on repeatability. A smaller total test volume yields a larger relative pressure decay value/signal and requires less test time. The greater the magnitude of the signal above zero, the better signal to noise ratio, which directly results in higher test accuracy and repeatability.

Moving the leak tester closer to the part under test will decrease test time and increase accuracy which raises both quality and throughput. The challenge is how to narrow that proximity when space is so limited? The answer is the iKit by Zaxis. At 1/4th the size of most pressure decay leak testers the iKit was designed specifically to fit within close proximity to the product under test on an assembly line. At only 3” wide the iKit can be mounted right on tooling saving valuable space and reducing excess test volume that is created by the use of extended hoses.

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Effective automation relies on effective communication. There are many components that go into an automated production line, all of which need to be able to talk to each other. Once a leak tester runs its test it needs the ability to communicate results or trigger events such as Pass=Next, Fail=Eject or Fail=Halt Production.

There are many forms of communication commonly used in factory automation including Modbus, Ethernet TCP/IP, and EtherNet/IPTM. The most dynamic of these communication systems is EtherNet/IPTM as it combines traditional Ethernet infrastructure and hardware with both of the most commonly used collections of Ethernet standards, the Internet Protocol suite and IEEE 802.3, and integrating the Common Industrial Protocol. EtherNet/IPTM is the preferred communication system for Allen-Bradley automation equipment.

With factory automation in mind, the purpose-built design of the iKit has the option to include EtherNet/IPTM. Other communication systems such as discrete I/O, RS232 and Ethernet TCP/IP are also available.

EtherNet/IP in Factory Automation

iKit Automation Solution

Zaxis has designed the iKit to be the ideal leak tester for factory automation settings. With the smallest footprint of any pressure decay leak tester on the market combined with integrated Allen-Bradley connectivity, the iKit by Zaxis is an excellent leak test solution for factory automation.

iKit by Zaxis

Manufacturing Electronic Sensor Catheters

Manufacturing Electronic Sensor Catheters

Isaac HD multi-function leak tester

Electronic ‘sensing’ catheters have become an integral component in both medical procedures and training. They give instantaneous information such as internal temperature, glucose levels, positioning, pressure and contact force between the catheter and tissue. This convenient and continuous information helps to eliminate invasive probing, increasing patient safety. Studies show improved patient outcomes after using contact-force sensing catheters.

Due to the growing number of sensing catheters, consistent and reliable manufacturing is vital. Leak testing both the catheter tubing and sensors needs to be accurate and precise. The Zaxis Isaac HD multi-function leak tester can be configured with multiple test types such as pressure decay, vacuum decay, pressure occlusion, and mass flow with less than 1 cm3 of internal test volume. An internal test volume of less than 1 cm3 increases the magnitude of the pressure decay value and decreases the overall time of the leak test, thereby improving the precision of the leak test.

In addition to the small internal test volume, the Isaac HD is extremely modular. You can add test types when you need them. With a multitude of test types at your disposal, the Zaxis Isaac HD is a perfect candidate for leak testing sensing catheters.


  1. Hoffmayer KS, Gerstenfeld EP “Contact force-sensing catheters” Jan 2015, https://www.ncbi.nlm.nih.gov/pubmed/25389646
Pressure Decay Test

Pressure Decay Test

What is a Pressure Decay Leak Test?

Pressure decay is one of the most widely used methods of leak testing in manufacturing and is ideal for a sealed component with an access port. In this test, a product is attached to a leak tester and filled with air. Once pressurized, the air source is valved off and the pressure is allowed to settle. During the test any decrease in air pressure over time signifies a leak. If the part does not leak/decay past its predetermined reject value, it is a good part. The sensitivity of this test is dependent upon the product’s size and the time interval of the test. Larger objects require a longer cycle time to reach a high enough sensitivity for a quality test. Smaller objects with small internal volumes will require very low cycle time, allowing a high throughput of production.

Here’s how it works:

  1. Connect your part to a Zaxis leak tester with a fitting or fixture. During the FILL stage your part is pressurized.
  2. Once the desired test pressure specified by the manufacturer has been reached and the fill time has ended, the SETTLE stage commences accommodating for part stretching or flexing.
  3. Once the part has settled and the settle time has ended, the pressure decay TEST initiates. During the test stage a pressure sensor will measure any drop in pressure.
  4. After the pressure decay test the remaining pressure in the system is vented to atmosphere during the VENT stage.
  5. If the pressure decay of your part remains within your specification then your part PASSES and a green light illuminates. If the pressure decay of your part falls below your lower limit, then your part FAILS and the red light illuminates.

The advantage of this type of testing is that it is accurate up to the 5th decimal place or 0.00001 PSI allowing for fast test cycles.

Sample Applications:

  • Catheters

  • IV Set

  • Tubing

  • Needleless Injection

  • Bag

  • Implantable Device

  • Infusion Set

  • Metering Device

  • Sensors/Indicators

Suggested Testers for Pressure Decay

Zaxis PD

Zaxis Pressure Decay Leak Tester
A wall mounted, lower cost, single channel alternative for manufacturing cell configurations.


A compact design that saves on valuable manufacturing space. Ideal for automation.

Isaac HD

Zaxis Isaac HD Multifunction leak tester
The modular design makes this mulit-tester the work horse of the leak tester family.

Zaxis 7i

Large feature capacity including a large, easy to use, color touchscreen.

Speak to a Specialist

We are here to answer any and all questions about leak testers and test types.