Leak Testing Solutions

Leak testing is essential in modern manufacturing; it enables the detection and measurement of leaks in sealed components and pressurized systems. At Averna, we develop automated leak testing systems designed for both R&D validation and high-volume production environments.

What is a Leak Test?

A leak test is a quality control process used to detect and measure leaks in sealed components or systems, ensuring reliable performance while meeting industry standards. It is an essential quality control measure, as it ensures not only the functionality of a product, but also its safety.

Leak testing typically involves applying controlled pressure or introducing a test medium into a sealed system to reveal any leakage paths. Subtle pressure variations or trace signals make it possible to detect microscopic defects, quantify leak rates and confirm the integrity of the assembly without affecting the product.

In environments where components must remain perfectly sealed, even minimal leakage can compromise performance or safety. This is why leak testing is used to validate tightness requirements and ensure consistent results before products reach real-world operating conditions.

Leak Detection Expertise At Averna

Leak detection is rarely a one-size-fits-all process. Each product has its own geometry, materials, sealing methods and acceptable leak rate. At Averna, we design leak testing systems that are adapted to these constraints, ensuring accurate and repeatable verification without impacting the product under test.

Our engineers develop test architectures capable of detecting extremely small leaks while maintaining the cycle times required in modern manufacturing. Depending on the application, our systems can validate seal integrity, measure leak rates or identify potential weaknesses in sealed housings and pressurized assemblies.

Automated for Production Environments

Leak testing does not stop at detection. In modern manufacturing, it must be integrated seamlessly into production workflows while maintaining speed and data consistency. Beyond the test itself, Averna focuses on integrating leak detection directly into the broader quality and manufacturing environment.

We develop systems designed for inline and end-of-line validation. Our automated test platforms are also built to handle high throughput requirements across large production volumes.

Each system is engineered to integrate with existing manufacturing environments, including automated handling, PLC-controlled sequences and centralized data acquisition.

Below are the industries where our leak testing expertise is most frequently applied.

Leak Testing Applications Across Industries

Consumer Electronics

Precision leak detection protects electronic devices from moisture ingress, dust and environmental exposure. Reliable sealing helps extend product lifespan and maintain performance in compact and sensitive electronic assemblies.

Examples: Cellphones, earbuds, smartwatches, speakers, home appliances and VR headsets.

Defense and Military

Leak testing for defense electronics ensures mission-critical systems remain protected in harsh environments. Reliable sealing prevents failure in sensitive communication, avionics and control equipment.

Examples: Ruggedized electronics, military communication systems, avionics modules and sealed control units.

Medical Devices

Medical device leak testing verifies seal integrity and ensures compliance with strict regulatory standards. Reliable leak detection helps protect sterile conditions and patient safety.

Examples: Pharmaceutical packaging, catheters, medical tubing, wearable monitors, implantables and respiratory devices.

Industrial Equipment

Industrial systems often operate under pressure or contain liquids or gases, making reliable leak detection essential for safe and efficient operation. Effective testing helps ensure system integrity and long-term reliability in demanding environments.

Examples: HVAC systems, EV chargers, power distribution equipment, switchgear and energy infrastructure components.

Automotive and EV

Automotive leak testing ensures the integrity of automotive and electric vehicle components exposed to pressure, temperature variations and fluids. Detecting leaks early helps manufacturers prevent safety risks and costly product failures.

Examples: EV batteries, power electronics, cooling systems, motors, A/C components, tubing and sealed housings.

Semiconductor Manufacturing

Semiconductor production relies on extremely precise environmental control, where even microscopic leaks can disrupt vacuum systems or contaminate processes.

Examples: Vacuum chambers, wafer handling systems, gas delivery systems and semiconductor process equipment.

Key Leak Testing Methods

Depending on the product or the required level of sensitivity, leak testing methods will vary. There are specific physical principles involved in detecting leaks. To provide you with the solution that best meets your needs, we place great emphasis on engineering prototyping and consultancy. Choosing the appropriate method ensures accurate results and production efficiency.

Patented Optical Leak Testing

Our cutting-edge optical leak detection technology offers a non-contact, highly sensitive solution for detecting exact locations of micro-leaks in sealed components. By leveraging advanced imaging and spectroscopy, this method enables real-time visualization of leakage paths and supports precise leak localization and micro leak detection.

Our patented process involves using a combination of pressurized gas, light, and automated visual inspection to detect the exact location of leaks, making it particularly effective for sealed electronic housing leak testing equipment, smartwatch leak test systems and other miniaturized assemblies where traditional leak detection methods reach their limits.

Pressure Decay Testing

Pressure decay testing measures the loss of pressure in a sealed system over time. Any variation indicates the presence of a leak and allows for pressure drop measurement and leak rate quantification.

This method is widely used for its simplicity, reliability and suitability for automated quality control in production environments.

Differential Leak Testing

A step above conventional pressure decay testing, differential leak testing compares pressure variations between a reference chamber and the test part. This method is exceptionally effective for high-speed, high-accuracy applications, allowing for faster cycle times and tighter tolerances in automotive, HVAC, and industrial manufacturing.

Vacuum Decay Testing

Vacuum decay testing operates by creating a controlled vacuum around or within the test part and monitoring pressure changes over time. Any increase in pressure indicates the presence of a leak entering the system.

This method is particularly effective for detecting small leaks in sealed components, especially when external influences must be minimized. Its stability and sensitivity make it well suited for applications requiring consistent and repeatable measurements without direct pressurization of the product.

Helium Leak Testing

Using helium as a tracer gas, this method detects even the smallest leaks in critical applications such as aerospace, semiconductor fabrication, and medical implants. It offers unmatched sensitivity and is ideal for ensuring hermetic seals in mission-critical products.

Water Leak Testing

Designed for products that require waterproofing validation, this test submerges components in water while applying air pressure, allowing bubbles to visually indicate leak points. It is commonly applied to automotive electronics waterproof leak testing and consumer electronics where liquid ingress must be prevented.

Tracer Gas and Mass Flow Leak Testing

Tracer gas leak testing introduces a specific gas such as helium or hydrogen into the system to detect leaks using dedicated sensors. This method supports hydrogen tracer gas detection, sniffer probe leak detection and infrared gas detection, depending on the setup and required sensitivity.

Mass flow leak testing measures the flow of gas required to maintain pressure, enabling precise leak flow measurement and improved leak analysis in controlled environments.

Build a Leak Testing System That Fits Your Production Reality

From high-volume production lines to specialized R&D testing, Averna’s leak detection solutions provide the performance and consistency required in production environments.

Our involvement can start early, when validation is still evolving, or later when production needs to scale. We work alongside your team to shape and integrate a solution that delivers results you can rely on, every time a unit is tested.