Effective leak testing is challenging, which is why the Zaxis team has your back through our industry-leading technology!

Leak testing systems require tech-savvy designs in order to meet strict reproducibility and reliability standards, which is why business leaders and manufacturing teams must rely on trusted specialists like the experts at Zaxis.

Whether you’re in the medical, automotive or consumer goods industries, you likely understand just how distressing leak test mistakes can be. Countless device manufacturers turn to our specialists to control their production costs and enhance their manufacturing efficiency, but it’s also important for business leaders to understand the basic fundamentals of what leads to cost-effective, accurate leak testing strategies.

Below are five key factors toward effective leak testing systems that device manufacturers often overlook!

1. Aligning Your Leak Test Specifications With Real-World Requirements

It’s possible for leak testing specifications to be incorrect when they’re either too strict or too lenient, which is why business teams must be extra careful while identifying their unique leak test specs.

For example, many medical device manufacturers will inadvertently keep their leak test specs too strict. This sometimes leads to compliant parts and devices being rejected, which can add up quickly in terms of your team’s materials and time.

On the other hand, overly lenient specs lead to headline-grabbing mishaps like lawsuits, product recalls, and negative brand reputations.

This complicated dichotomy is why we can’t stress enough how important it is for businesses to accurately define their leak test specs based upon their product’s real-world requirements, because this is the first step toward designing appropriate test methods.

For instance, if your part needs to function correctly at very high pressures, you’ll likely be better off with downstream test methods like mass flow leak tests through cutting-edge products like the Isaac HD or Zaxis 7i.

2. Custom Leak Testing Software Is Essential For Your Manufacturing Line

It’s a widespread misconception throughout various industries that businesses can cut costs by using generic software for their unique manufacturing needs. Custom software engineering always goes a very long way to lower manufacturing costs, while also adhering to leak testing best practices.

Even if you produce low-cost products that require high-speed testing, relying too heavily on generic leak testing software can lead to many issues. This is why it’s important for business leaders to put their trust in real-time operating systems that are specifically designed for industrial environments!

3. Consistently Calibrate Your Entire Leak Test System

Businesses also need to ensure that their leak testing’s traceability and calibration is straightforward, because complicated calibration can slow down your team’s production and lead to inaccurate test results.

It’s a common mistake among manufacturing teams to assume that a calibrated leak detector guarantees a fully calibrated leak test system. This is because well-calibrated leak detectors are essentially useless if they coincide with packaging issues like seal creep, punctures or flex cracking.

Consistently calibrating your entire leak test system will ensure the long-term efficiency of your production line!

4. Your Leak Test Fixtures Must Meet R&R Requirements

Generic leak test fixtures often won’t meet reliability and reproducibility (R&R) requirements, especially for test applications with tight tolerances and rigorous specs. A lot of manufacturing companies that try to cut corners by spending less on their leak test fixtures often end up spending more to rework their systems.

Being realistic about your company’s fixture requirements will always benefit you and your team in the long run through cost savings and more accurate results.

5. Quality Assurance Relies Heavily Upon Component Traceability

A lot of businesses overlook the importance of controlling costs when it comes to their leak testing systems.

This is why many device manufacturers will prioritize traceability by logging test data based upon part numbers. This type of traceability data also goes a long way toward streamlining your entire production line. It also helps ensure that you’re abiding by ISO regulations and guaranteeing your overall quality assurance.

The good news is that there are many affordable ways to improve your component traceability, including bar code labeling and laser-marking systems.

Securely archiving your leak test data for future analysis can also help you minimize product defects, maximize production yields, and guarantee that faulty products never get released into the marketplace.

Have Questions About Improving Your Leak Testing Systems? Contact The Zaxis Experts Today!

It’s essential for business leaders to be informed about cost-effective, efficient leak testing strategies, and this is especially the case when in-house specialists aren’t on your payroll.

Zaxis supports manufacturing businesses all around the world, and our renowned industry experts are always available to answer your questions and point you in the right direction toward improving your leak testing systems and strategies.

Reach out to us online or give us a call at 801-264-1000 today to let us know how we can support your company’s leak testing needs!