Leak testing is a method of product quality control that identifies manufacturing inconsistencies by porosity testing a manufactured part or system leaks. This nondestructive test is typically accomplished by sealing any ports or holes the test product might have and then introducing a test medium—usually air, nitrogen or helium—into or around the test piece. From there, a trained operator or a leak test instrument will be able to observe any leaks coming into or out of the product.
A leak test can be performed at various stages throughout the manufacturing process. Many original equipment manufacturers (OEMs) require that components be leak tested to ensure integrity before assembly. The OEM might also perform a leak test on the entire system during different stages of assembly to ensure an optimal, safe product for the end user. Similarly, a leak test might be used at various times during a product development process to bench test prototypes. Throughout this article, we will cover important considerations when implementing a leak testing process, as well as some key trends in the leak testing industry.