Helium Leak Testing
High-sensitivity helium leak testing ensuring sealing reliability for battery enclosures, liquid cooling plates, and high-integrity thermal systems.
What Is Helium Leak Testing
Helium leak testing is a high-sensitivity, non-destructive testing method used to detect micro-leaks in sealed components. Compared to air or water testing, helium testing provides much higher detection sensitivity, accurate quantitative leak rate measurement, and reliable validation for safety-critical systems.
Why Helium Leak Testing Is Critical for Battery Systems
Battery enclosures and cooling plates must remain sealed throughout their service life. Helium leak testing is the industry-standard method to ensure long-term sealing reliability for safety-critical battery and thermal systems.
Our Role in Helium Leak Testing
We provide helium leak testing as part of integrated manufacturing and validation workflows—not as a standalone inspection step. Our work includes method selection, fixture and interface preparation, process integration into production, and result interpretation with documentation.
Typical Components Tested
Helium leak testing is applied to sealed components with internal channels or cavities—especially cooling plates and sealed enclosures.
Leak Rate Sensitivity and Control
Our testing supports high-sensitivity leak detection, typically down to ≤ 1 × 10⁻⁵ mbar·L/s (project-dependent). This sensitivity is commonly required for liquid cooling systems, long-life sealed enclosures, and automotive / energy storage applications.
- • Cooling channel sealing
- • Sealed enclosures
- • Safety-critical systems
Test Methods and Approaches
Helium leak testing can be performed using different methods depending on component design. We select the approach to balance accuracy, speed, and production efficiency.
Integration with Welding and Machining Processes
Helium leak testing is closely linked to manufacturing processes. We coordinate testing with FSW welding, vacuum brazing, and CNC machining of sealing interfaces—so the test validates real production conditions, not isolated samples.
Sealing Interface Design Validation
Leak testing validates the effectiveness of sealing features—gasket grooves, O-rings, weld seams, and brazed joints. Results provide direct feedback for design optimization.
In-Process vs. Final Leak Testing
Leak testing can be applied at different production stages. In-process testing after welding or brazing helps identify root causes early, while final testing after full assembly provides end-of-line confidence.
Quality Control and Traceability
Leak testing results are part of the quality system: recorded leak rates, pass/fail criteria, batch-level traceability, and integration with inspection reports—supporting audits and customer validation.
Production Scalability and Throughput
Helium leak testing is designed to support prototype/pilot production and series manufacturing. Workflows are optimized for repeatability, cycle time control, and consistent test conditions.
Typical Application Scenarios
Helium leak testing is widely used across EV and ESS systems, heavy-duty vehicles, industrial liquid-cooled components, and marine/outdoor power systems.
Relationship with IP Rating and Environmental Testing
Helium leak testing complements IP testing. Helium detects micro-leaks and quantifies leak rates, while IP tests validate water and dust ingress protection under defined conditions. Together they provide a comprehensive sealing validation strategy.
Why Choose Us for Helium Leak Testing
We combine high-sensitivity detection with manufacturing integration—so leak validation is repeatable, scalable, and supported with clear documentation.
Contact & Testing Consultation
Upload your drawings (STEP / DWG / PDF) for test method selection, fixture planning, leak criteria definition, and production workflow evaluation.