Q&A: With the Cost of Helium Continuing to Rise, How Can Industrial Leak Detection Reduce Costs? Leak Tester Emerges as the Optimal Solution for Mass Production

In the field of industrial leak detection, there has long been a tacitly accepted assumption:The higher the precision, the more reliable the quality.. Because in the pastAirtightness TesterThe technical precision is indeed limited, so many manufacturing companies have no choice but toHelium Leak DetectorAs “Safe Bet"—Better to pay the price for excessive accuracy than to risk missing something."

But this logic is quietly being rewritten.

With the continuous advancement of compressed air leak testing technology, the accuracy of testing methods such as the direct pressure method, differential pressure method, and flow method has improved significantly, making them sufficient to meet the vast majority of industrial-grade sealing requirements. A key understanding is taking shape:当airtightness meterWhen the accuracy is already sufficient to meet the requirements of the product’s actual usage scenarios, continue to pursuehelium detectorExtreme accuracy is, in essence, a form of “over-detection.”The

This means that products that previously had to rely on helium testing due to precision requirements now have a more cost-effective alternative. For manufacturing companies seeking to control costs and maximize production line efficiency, it is time to reevaluate “The Balance Between Accuracy and Cost", is becoming an urgent issue.

I. The Real-Life Challenges Faced by a Quality Control Manager

Mr. Li, the quality manager at a new energy battery company, is facing a tricky selection dilemma.

Their battery casings require high-reliability leak testing. For many years, this process has been running smoothly:Fill the product with helium → Inspect for leaks using a helium mass spectrometer → Determine if there are any leaks. From a technical standpoint,Helium Mass Spectrometry Leak DetectionIt has always been the solution he trusts.

But the problem is:Helium is becoming more and more expensive, and its supply is becoming increasingly unstable.

Global helium supplies are beginning to fluctuate. Production capacity in major helium-supplying regions, such as Qatar, has been affected; international supply chains are facing disruptions due to geopolitical factors; and helium export policies are also changing in some regions. For manufacturing companies that rely on helium,These uncontrollable cost variables are eroding profit margins.

Old Li began to reexamine a core issue:Do all products on the production line require the use of an extreme-grade helium mass spectrometer for leak detection?
This question is also becoming a common concern among many manufacturing companies.

II. The Working Principle of Helium Mass Spectrometry Leak Detection

To understand why helium testing was once so popular, you need to understand how it works.

Helium Mass Spectrometry Leak DetectionUsing the tracer gas method.When a product has a minor leak, the helium that has been injected enters the detection system through the leak point, and the mass spectrometer determines whether there is a leak, where the leak is located, and how much helium is leaking by measuring the concentration of helium ions.. This technologyIt is extremely sensitive and can detect even the tiniest theoretical leaks.The

It is precisely because of this capability that helium testing is virtually irreplaceable in certain fields:

Vacuum chambers must prevent even the slightest ingress of gas. Aviation hydraulic systems require extreme sealing reliability. Semiconductor manufacturing is extremely sensitive to impurities. The cost of failure for high-end medical equipment is incalculable.

In these areas,There is no testing method more rigorous than helium testing.. It used to be the ultimate guarantee of quality.

III. The Overlooked Truth: Most Mass-Production Scenarios Do Not Require Extreme Precision

But Old Li realized something that had been overlooked: many of the products on their production line,In fact, this level of detection accuracy is not necessary.

The requirements that a battery casing must truly meet are:Waterproof, moisture-resistant, prevents air leakage, and ensures long-term sealing reliability. Its detection objective isEnsure that the product does not leak in actual use, rather thanDetermining Whether It Is Theoretically Possible to Detect Extremely Small LeaksThe

This is a crucial shift in thinking.

When you’re manufacturing consumer batteries at a rate of several thousand units per day, rather than an aviation device worth several million yuan,The cost pressures resulting from excessive precision have become unreasonable.

This prompted Old Li to start looking for a way to...An industrial leak testing solution that does not rely on helium and meets mass production requirementsThe

IV. Compressed Air Leak Testing: An Alternative Approach

The alternative approach is actually not that complicated:Compressed air is used in place of helium as the test medium to accurately assess seal performance based on changes in pressure.The

Jingcheng Engineering's Explosion-Proof Diaphragms for Battery CoversAirtight Breathing Blaster

From a physical and logical standpoint,Anywhere water can seep through, gas can pass through as well.. Gases are more sensitive than water and can detect even the slightest defects, making them sufficient to meet the vast majority of industrial-grade sealing requirements. Currently, the mainstream principles of airtightness testing based on compressed air fall into three technical categories:

• direct pressure: Compressed air at a set pressure is injected into the workpiece, and the rate of pressure decay is monitored during the pressure-holding phase; if it exceeds the threshold, a leak is detected. This solution is simple and easy to implement, and is suitable for applications such as home appliances, 3C consumer electronics, and security and lighting systems.
• differential pressure: Gas is simultaneously introduced into the standard chamber and the workpiece under test, and micro-leaks are detected by comparing the pressure difference between the two. With strong resistance to environmental temperature drift and high repeatability, this method is the preferred choice for applications requiring high consistency, such as automotive components, new energy batteries, and precision die-cast parts.
• flow rate method: By measuring the airflow passing through a leak point per unit of time, this method directly quantifies the size of the leak and is suitable for testing special components such as breathing valves, waterproof breathable membranes, and capillary tubes.

V. Who Should Opt for Air Tightness Testing?

Helium testing is not required in all situations; in the following areas, airtightness testing fully meets quality control requirements:

• New Energy: Products such as battery housings, battery packs, and energy storage cabinets that require waterproofing and moisture protection but do not require vacuum-level sealing;
• Auto Parts: Components such as connectors, valve bodies, and sensors, where IP protection ratings and long-term reliability are critical;
• Consumer Electronics: Mass-produced products that meet industrial-grade waterproofing standards, such as mobile phone structural components and smart wearable devices;
• Medical Equipment: Products such as piping and sealed chambers, where batch consistency and data traceability are critical;
  ......

For production lines that produce thousands or even tens of thousands of units per day,Airtightness TesterProvided that quality control standards are met,It can significantly reduce operating costs, and its overall advantages are quite significant.The

VI. Jingcheng Engineering Solutions: Why They Are the Choice for Companies Seeking to Reduce Costs and Improve Efficiency

Why are more and more manufacturing companies choosing JCGK’s airtightness testing solutions? The reason is quite simple.

1. Eliminate dependence on specialty gases and keep operating costs under control

Using standard compressed air as the testing medium eliminates the need to purchase helium, completely removes the risk of fluctuations in gas supply and the rising costs of consumables, and significantly reduces long-term operating costs.

2. Automated native adaptation; end-to-end solution delivery

The equipment comes standard with PLC communication, Profinet bus connectivity, and MES system integration capabilities, and supports QR code traceability, automatic loading and unloading, and parallel inspection across multiple stations. Jingcheng Engineering can provide “Testing Equipment + Custom Fixtures + Automation Integration"… an end-to-end solution that seamlessly integrates the inspection process into existing production line workflows."

3. Suitable for high-volume production at a fast pace, resulting in lower unit costs

Multi-channel equipment enables simultaneous inspection of multiple workpieces, with an inspection cycle per workpiece ranging from a few seconds to several tens of seconds, making it perfectly suited for high-volume production; it eliminates the need for additional processes such as helium recovery and workpiece post-processing, further reducing the cost per workpiece.

VII. Rational Selection: Matching by Scenario, Not an Either/Or Choice

After careful consideration, Old Li did not simply assume that “The helium test didn't go well". His choice was more rational:

Continue using helium testing where appropriate, and use methods better suited for mass production where gas testing is required.

For small quantities of products that require extremely high reliability, the accuracy assurance provided by helium testing is maintained.For standard products manufactured in large volumes, fully transition to JCGK’s compressed air leak testing solution.The

The results are obvious:This has reduced reliance on helium, increased inspection throughput, lowered maintenance costs, and made production line operations more stable.

This isn't just a simple “Replace"decision, but rather"A New Understanding of Different Products and Different NeedsThe

Conclusion

Against the backdrop of global supply chain volatility, the core competitiveness of manufacturing companies has long extended beyond simply mastering a single advanced technology; it now lies in having a diverse range of technological options at their disposal.

In the future of industrial leak detection, one technology will not completely replace another; instead, technologies will be adapted as needed:For applications requiring extreme precisionHelium Leak DetectorEnsuring reliability for mainstream mass production scenariosAirtightness TesterBalancing Cost and EfficiencyThe

Leveraging a comprehensive technology portfolio that includes direct pressure, differential pressure, and flow measurement, combined with its capabilities in custom automation integration, JCGK is helping an increasing number of manufacturing companies reduce their reliance on imported equipment and specialized consumables and build more resilient quality control systems.
In times of uncertainty, having reliable and diverse technology options is a company’s most solid foundation for weathering risks.

Original Statement:this paper was written byShenzhen Jingchenggongke Technology Co., Ltd.Written by the technical team, reproduced with attribution.Data sources: Precision Engineering internal test data and customer cases.