Which products must be tested for airtightness and waterproofing? Read this 'Manufacturing Leak Detection Guide' and you'll be satisfied!

The smartphone you hold in your hand, the electric car you drive, the smartwatch you wear, they all have one feature in common: they all have to undergo a rigorous airtightness test before they leave the factory.

Thirty years ago, airtightness testing was reserved for a few high-end products. Today, it has permeated virtually every product that is important toWaterproof, dustproof, leakproof, pressure resistant or life time stableThere are requirements in the product.

Behind this shift is a simple but profound truth:The verification of product safety and reliability is increasingly dependent on precise control of sealing performance.. Airtightness testing has evolved from a separate quality control process to an indispensable part of the product quality assurance system.

So, which products actually need air tightness testing? Let's start by exploring the most critical areas.

Ⅰ. New energy industry: safety and consistency are the bottom line

In the new energy sector, airtightness testing is particularly critical for one reason:Safety is not trial and errorThe

Common test objects include:

• Battery Pack, Power Battery Case, Cell, Top Cover
• Battery Module and PACK Structure
• Cooling plate, water circuit system
• Sealed cavities for energy storage devices

Detection purpose:

• Prevents electrolyte leakage
• Avoid short circuits caused by water vapor intrusion
• Verification of voltage withstand and structural integrity

Inspection solutions for the new energy industry

Precision EngineeringA complete matrix of solutions has been formed in the new energy industry: from conventionalAir tightness testingto a professionalRespiratory cycle testFrom the limits of theBursting pressure resistance testTo sophisticatedHelium Detection ProgramEach detection method is designed for a specific failure mode.

This all-round testing capability ensures the reliable operation of new energy products under various extreme conditions.

Ⅱ. Automotive Parts: From "Waterproofing" to "Total Vehicle Reliability"

There are far more parts in a car that really need to be tested for airtightness than one might think.

Typical applications include:

• Automotive lamps and lanterns(headlights, taillights, ambient lighting)
• Sensor, control module housings
• Wire Harness Connectors, Valve Body, Lines
• Motor, electric drive, electric control system related components

Detection value:

• Ensure long term stability in rain, car wash and high humidity environments
• Avoid failure of electronic components due to micro leakage
• Meet OEMs' stringent quality consistency requirements

automobile thermostatFour-channel airtightness testing machine

In the field of automotive components.Stability, repeatability and beat controlOften it is more important than the accuracy of a single inspection. A production line inspects tens of thousands of parts per day, and any misjudgment or omission can result in huge losses, which is exactly what theAir tightness testing equipmentCore considerations for selection, andPrecision EngineeringAlways use this as a standard to create a reliable inspection program.

III. Consumer electronics: small size, rather higher requirements for sealing

Consumer electronics are getting smaller and smaller, but the environments in which they are used are getting more and more complex.

Commonly tested products:

• Smartphones, tablets
• Smart Wearable Devices, GPS Watches
• Bluetooth speakers, wireless headphones, sound cavity structure
• Camera modules, micro housings

Why is an airtightness test necessary?

• IP waterproof rating has become a selling point
• Small internal space, highly susceptible to failure due to water vapor
• Batch shipments with high demand for consistency

Consumer ElectronicsDual-channel airtightness tester

In the high-speed production lines of consumer electronics, thePrecision EngineeringThe airtightness testing technology has been battle-tested for a long time.Whether it's positive/negative pressure, volumetric, flow or differential pressure, each detection method has been polished through a large number of production scenarios.. itsstand aloneMulti-Channel Airtightness TesterIt is not only able to accurately control the sealing quality of each product, but also can easily cope with the demand for high production capacity of thousands of pieces per hour.Perfect balance between precision and efficiencyThe

Ⅳ. Medical equipment: air tightness, directly related to the use of safety

The requirement for airtightness testing of medical devices is often more than just "thewaterproofing", moreoverPart of Security ComplianceThe

Application scenarios include:

• Disposable medical consumables
• Respiratory equipment and tubing
• Infusion, oxygenation, negative pressure equipment
• Closed-cavity diagnostic equipment

Core Claims:

• Preventing cross-contamination
• Ensure accurate pressure control
• Meet regulatory and certification requirements

Medical EquipmentSealing Tester

In the medical industry, testing equipment forStability and traceabilityDirectly determine the bottom line of product quality, air tightness testing has become a mandatory inspection program for all types of medical products. In the face of the demand for batch testing of medical products, thePrecision Engineering'sAir tightness testing equipmentWith stable performance, it guarantees accurate and consistent test results, while helping medical companies easily meet industry compliance requirements through a comprehensive data traceability system.

V. Security lighting and outdoor equipment: the environment is the biggest test

Outdoor equipment is exposed to wind, rain, temperature differences and dust for long periods of time, placing higher demands on the sealing structure.

Commonly detected objects:

• Outdoor camera
• Security ball and PTZ equipment
• Street light, landscape light, industrial and mining light, wall washer light
• Outdoor sensing and communication equipment

Detection purpose:

• Verification of protection class IP66 / IP67 / IP68 etc.
• Identify assembly defects and seal failure risks
• Reduce after-sales repair rate

surveillance cameraAirtightness Tester

For security lighting products, airtightness testing isCritical screening prior to waterproof testingwhich can effectively circumvent the waste of time and cost of subsequent water testing.Precision EngineeringThe detection technology makes this screening process more accurate and efficient.

VI. Robotics and automation equipment: the basic guarantee for reliable operation

As industrial and service robots become more popular, the importance of airtightness testing is increasing.

Related applications include:

• Joint Module
• Drive unit housing
• Sensor Components
• Protective housing

Why do we need to test the airtightness?

• Dust, oil and moisture resistant
• Ensure long-term continuous operation
• Reduced maintenance frequency

Sweeping robot factory line solution

In robotics and automation scenarios, the central role of airtightness testing is to "Early detection of hidden dangers」，Precision EngineeringWe are deeply committed to this field and protect the safety of equipment with efficient inspection technology.

VII. Aerospace Military Industry and High-end Equipment: Reliability Verification in Extreme Environments

In high-end fields such as aerospace and military industry, airtightness testing is more in favor of theStructural Integrity and Safety VerificationThe

Common needs include:

• sealed cabin
• piping system
• Pressure and Leakage Verification
• Vacuum or high pressure environment simulation

Nitrogen Filling Tester for Military Industry

This type of application has a significant impact on the testing equipment'sPrecision, Stability and Safe DesignThe requirements are extremely high.Precision EngineeringWith professional technology accumulation, we provide accurate and stable detection solutions for such high-end scenes.

VIII. Why are more and more industries moving away from airtightness testing?

Looking back at the penetration of airtightness testing in various industries, a clear pattern of evolution can be found:The smaller the product and the more complex the sealing structure, the more indispensable airtightness testing becomes.The

Thirty years ago, appliances were large and simple, and waterproofing depended mainly on thick housings and simple seals. Even small sealing defects did not immediately lead to functional failure.

Today's smart devices are ten times smaller in size and a hundred times more powerful. With this extreme space utilization, any little sealing defect can be fatal.

The harsher the use environment, the higher the reliability requirements, the more the value of airtightness testing is highlighted.

Consumer electronics products from indoor to outdoor, automobiles from fuel to electric, medical equipment from simple to precision - each expansion of the product application scenarios, the sealing performance put forward higher requirements.

The higher the manufacturing costs and the greater the after-sales risk, the more obvious the economic value of airtightness testing becomes.

A power battery can cost thousands of dollars and a medical device can be worth millions. If these products fail in use due to sealing problems, the cost of recalls and compensation will far exceed the cost of testing.

This triple logic works together to promote airtightness testing from the exclusive use of a few high-end products, evolving into the modern manufacturing industry'sstandard configurationThe

IX. Precision Engineering: more than ten years of deep plowing, building a complete testing ecology

As a domestic gasTightness Testerof industry leaders.Shenzhen Jingchenggongke Technology Co., Ltd.(JCGK)Witnessed and participated in this evolution of detection technology.

Not just an equipment supplier, but a solution provider

The value of Precision Engineering lies not only in the provision of high-precision testing equipment, but also in understanding the actual needs of different industries and transforming testing technology into implementable engineering solutions:

For the new energy industryWe provide a full chain of testing solutions from cell to PACK, covering a wide range of testing needs such as airtight, breathability, burst, pressure resistance, helium detection, and so on.

automotive industryIn addition, we develop high-speed inspection systems for automated production lines, realizing the perfect balance of stability, repeatability, and beat-to-beat.

For consumer electronicsThe design of positive and negative pressure, flow, volumetric, differential pressure and other detection methods meets the differentiated needs of flagship to entry-level products.

For medical devicesThe company has established a complete data traceability system to ensure that every test complies with regulatory requirements.

Technology accumulation translates into industry insights

More than ten years of deep plowing in the industry has allowed Precision Engineering to not only master the inspection technology itself, but also understand the engineering logic behind the technology:

• What kind of detection accuracy is really necessary?
• How do you balance the cost of testing with the risk of quality?
• What equipment configuration is best for the current production line?
• When should I upgrade my testing program?

The answers to these questions are hidden in theCountless in-depth conversations with customersHidden in theOf the tens of thousands of test data analyzedHidden in theOngoing tracking of industry trendsThe

Summarize

From new energy to aerospace military industry, from consumer electronics to medical devices, airtightness testing has become an indispensable means of quality assurance in modern manufacturing.

When you use a smart device in your hand, drive an electric car under your feet, or wear a smartwatch on your wrist, you may not realize that these products have undergone rigorous airtightness testing. But it's the unseen quality control that holds up the world of products we trust.

JCGK will continue to specialize in the field of airtightness testing.In addition, it serves manufacturing upgrading with technological innovation, solves practical problems with engineering wisdom, and constructs a more reliable quality line of defense together with partners from various industries.

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.