Integrating leak testing into a production line is often more complex than simply installing a standalone machine or test station. When key factors are overlooked—such as upstream conditions, test method selection, fixturing design, scalability, or proper validation—the result can be false failures, unreliable data, and costly production disruptions.
Too often, these issues stem from overlooked challenges and decisions made early in the design phase or from rushing implementation to meet launch deadlines. By understanding what not to do, manufacturers can avoid common pitfalls and ensure accurate, repeatable, and production-ready leak testing from day one.
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1. Ignoring processes that occur before the leak test station
The processes the part going through before the leak test station can have a huge impact on leak test results. For example, when using the pressure decay leak testing method, it is very important that the part is free of moisture and is at room temperature. Unfortunately, part design and upstream processes can easily lead to moisture or fluid being caught in a part, and many factors can lead to a heated part—both situations which would greatly skew leak test results if using pressure decay. Manufacturers need to be aware of this before designing the leak test process and choosing the test method.
2. Choosing the wrong leak test method
In some instances, there could be various different test types used for a leak test. However, circumstances can dictate when one may be better than the other. For example, you could have an application that seems like a good fit for pressure decay leak testing. However, if you have to consider environmental conditions, vacuum decay leak testing could be the better option for a reliable, repeatable leak test. Vacuum decay leak testing is as sensitive as pressure decay testing, but also less susceptible to temperature effects, making it a good option for leak testing applications where temperature control, etc., may be a challenge.
3. Poor fixturing and part presentation
Even the most advanced leak test system will struggle to deliver consistent results if the fixturing and part presentation are not properly engineered. Inconsistent seal compression, unsupported parts, or “floating” seals without hard stops can introduce cycle-to-cycle variation that affects repeatability and leads to false failures or masked leaks.
CTS designs seals integrate hard stops into the fixturing to ensure the optimal compression ratio every time, reducing variability caused by operator influence or part tolerances. Additionally, CTS leak test machines feature a unique air-proofing technique, using an extra pressure switch to confirm that air reaches the part immediately and correctly at the start of the test, to help prevent misreads caused by delayed or incomplete pressurization. Proper fixturing, verified air delivery, and purpose-built sealing solutions are essential to achieving accurate, reliable leak test results.
4. Designing leak test stations without future-scale flexibility
Leak test stations are often designed around immediate production needs, but failing to consider future models, higher throughput demands, or automation plans can lead to costly redesigns down the road. As programs evolve, cycle time requirements may shrink, part geometries may change, or additional test parameters may be introduced. If the original system was not built with flexibility in mind—such as modular tooling, adaptable fixturing, scalable controls, or automation integration—it can quickly become a bottleneck. Planning ahead is a strategic measure to ensure the leak test station remains efficient, adaptable, and capable of supporting long-term production goals without major reinvestment.
5. Rushing validation and runoff process
The validation and runoff phase is critical to ensuring a leak test system performs reliably in production. When this stage is rushed, important steps such as optimizing cycle time, conducting a thorough repeatability study, and confirming overall system capability may not receive the attention they require. Proper validation also includes verifying form and fit, as well as evaluating operator ergonomics to ensure consistent, repeatable part loading. Without a methodical runoff process, issues that could have been resolved early may surface later as false failures, inconsistent results, or production slowdowns.
Work with CTS to avoid common leak test pitfalls
Avoiding these costly mistakes starts with choosing the right leak test partner. With over 40 years of experience designing and integrating leak test systems, CTS helps manufacturers anticipate challenges, select the right test methods, engineer reliable fixturing, plan for future scalability, and execute thorough validation and runoff processes. If you’re planning a new system or optimizing an existing one, contact CTS to help you build a solution designed for long-term success.
Contact us today to speak with a leak test expert about your test!
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