Hydrogen Leak Testing | Fuel Cells and H2 Parts

Testing systems for fuel cells, electrolyzers, hydrogen storage and H₂ components

Green hydrogen is an important component of the energy transition. It opens up new possibilities for industry, the transport and logistics sector, energy storage and sector coupling. For hydrogen technologies to be used safely, efficiently and economically, the components involved must meet the highest requirements for tightness, quality and process reliability.

MACEAS develops high-performance leak testing systems for central applications of hydrogen technology – from bipolar plates for fuel cells and electrolyzers to hydrogen pressure vessels and cryogenic hydrogen tanks and other H₂-carrying components.

Why leak testing is crucial in hydrogen technology

Hydrogen places particularly high demands on material, design and quality assurance. The gas is very light, readily diffuses and can escape quickly in the event of leaks. At the same time, many hydrogen systems operate at high pressures, demanding media routing or sensitive electrochemical processes.

Reliable leak testing is therefore essential to ensure the functionality, safety, service life and efficiency of hydrogen systems. Even small leaks can impair the performance of fuel cells or electrolyzers, cause pressure losses or create safety-relevant risks.

MACEAS supports manufacturers and development departments with customized testing systems tailored to component geometry, material, test gas, leak rate, cycle time and degree of automation.

Typical areas of application

fully automatic helium leak testing of bipolar plates

semi-automatic leak testing of bipolar plates for development and small series

leak testing of bipolar plates made of metal or graphite

testing of bipolar plates with and without seals

testing of components for fuel cell stacks

testing of components for electrolyzer stacks

leak testing of hydrogen pressure vessels

leak testing of cryogenic hydrogen tanks

testing of valves, connections and H₂-carrying components

test concepts for storage technology, peripherals and media-carrying assemblies

MACEAS advantages

Hydrogen & Energy Systems

customized testing systems for hydrogen applications

suitable for fuel cells, electrolyzers, storage technology and H₂ components

very precise leak testing with helium and helium mixtures

fully automatic and semi-automatic system concepts

short cycle times for industrial series processes

objective, reproducible and documentable test results

integration into production lines and quality processes possible

testing systems for high volumes, samples, prototypes and small series

support with test strategy, fixture, handling and automation

scalable concepts from testing service to own series testing system

Test methods

Leak testing of bipolar plates

Bipolar plates are central components of fuel cells and electrolyzers. They perform important functions for media routing, electrical conductivity, heat dissipation and mechanical stability within the stack. Accordingly, the requirements for the tightness of the plates and their channel structures are high.

MACEAS offers fully automatic and semi-automatic leak testing systems for bipolar plates made of metal or graphite – with or without seals on the bipolar plate. The test can be designed so that relevant media spaces, channel structures, sealing areas and interfaces are reliably evaluated.

Leak testing of bipolar plates is particularly important to detect internal and external leaks early. This allows manufacturing defects, material deviations or process fluctuations to be identified before the components are integrated into stacks.

Practical example: Helium leak testing of bipolar plates

MACEAS realizes high-performance testing systems for industrial testing of bipolar plates. A typical system concept enables short cycle times and high volumes with reproducible test reliability.

Technical example data:

effective cycle time: 12 seconds
capacity: 300 parts per hour
Test gas: 10% helium / 90% air
leak rate: 4.8 × 10⁻⁵ mbar · l/s
test method: helium leak testing
design: fully automatic or semi-automatic
suitable for bipolar plates made of metal or graphite
testing with or without seal on the bipolar plate

This example shows how high test sensitivity, short cycle times and industrial automation can be combined.

Leak testing for electrolyzers and fuel cells

Electrolyzers and fuel cells consist of numerous precisely joined and media-carrying components. In addition to bipolar plates, seals, frames, housings, distribution structures, connections, cell modules or stack components can also be tested for tightness.

Depending on the component and test objective, different test methods can be used, such as helium vacuum leak testing, helium sniffing or other application-specific test methods. It is crucial that the test realistically reflects the later function of the component and at the same time can be reliably integrated into the production process.

Typical test objectives are:

detection of external leaks
detection of internal leaks between media spaces
securing of sealing and joining areas
testing of channel structures and media routing
evaluation of components before stack assembly
quality assurance after forming, joining or coating processes

Leak testing of hydrogen pressure vessels and H₂ storage

Hydrogen storage is one of the most demanding areas of hydrogen technology. Pressure vessels, tanks, valves, connections and peripheral components must be permanently tight and safe – even under high pressures, changing load conditions and demanding environmental conditions.

MACEAS develops test solutions for hydrogen pressure vessels and for components of storage and supply technology. These include among others:

hydrogen pressure vessels
cryogenic hydrogen tanks
valves, fittings and connection components
pressure regulators and media-carrying assemblies
pipe and line systems
container and tank components
interfaces between tank, peripherals and supply system

Depending on requirements, leak testing can be performed at component level, assembly level or as part of an end-of-line test.

Cryogenic hydrogen tanks and demanding storage technology

Cryogenic hydrogen storage places special demands on tightness, insulation and material resistance. Components must not only be gas-tight, but also take into account thermal loads, temperature changes and special operating conditions.

MACEAS brings experience in testing vacuum-insulated and double-walled systems. For corresponding applications, individual test concepts can be developed that are tailored to component size, test volume, test pressure, leak rate and handling.

Especially with cryogenic tanks and complex storage assemblies, a careful test strategy is crucial to reliably ensure quality and safety.

Test methods for hydrogen applications

Different methods are available for leak testing in hydrogen technology. The selection depends on the component, the required leak rate, accessibility, the production process and the desired degree of automation.

Typical test methods are:

helium vacuum leak testing for particularly sensitive and reproducible tests
helium sniffer testing to locate leaks on accessible component areas
tests with helium mixtures for economical and process-oriented quality assurance
automated test processes for high volumes and short cycle times
customized test concepts for stack components, storage technology and H₂ peripherals

Helium is particularly suitable as a test gas because it makes even the smallest leaks detectable and can be used for very precise leak testing.

Leak testing of bipolar plates as a testing service

In addition to building customized testing systems, MACEAS also offers a specialized testing service for bipolar plates. This service is particularly suitable for samples, prototypes and small series.

Especially in early development phases, setting up your own testing system is often uneconomical or not sensible in terms of time. With the MACEAS testing service, you can have your bipolar plates tested externally and quickly receive reliable results for development, optimization and quality assurance.

Why our testing service?

When developing new fuel cell or electrolyzer components, designs, materials, manufacturing processes and sealing concepts often have to be checked and adjusted several times. The MACEAS testing service enables you to carry out these tests flexibly without having to invest immediately in your own testing technology.

We test samples, prototypes and small series reliably for tightness and support you in identifying design or manufacturing weaknesses early. This allows development processes to be accelerated and technical risks to be reduced.

What we offer

testing of samples and prototypes
leak testing of small series
testing of metallic and graphitic bipolar plates
testing with and without seals on the bipolar plate
detection of design and manufacturing weaknesses
modern test methods and proven testing technology
fast, precise and traceable test results
support in evaluating suitable test parameters

Your benefits in the testing service

no own testing system required in the development phase
cost-effective testing of samples, prototypes and small series
fast feedback for development and quality assurance
specialized know-how in testing bipolar plates
high significance for product release, process optimization and pre-series
flexible support with fluctuating testing requirements
opportunity to experience MACEAS high-performance testing systems in action

The testing service can also be used to test and see our high-performance testing systems in real operation. This way you not only receive test results for your components, but also a practical impression of how modern leak testing can be integrated into your own production.

Good reasons for MACEAS

Quality assurance along the hydrogen value chain

Hydrogen technologies are in many areas between development, industrialization and scaling. Accordingly, testing technology is important that is both flexible enough for prototypes and small series and powerful enough for later series processes.

MACEAS supports customers along different development and production phases:

feasibility testing and test concept
prototype and sample testing
small series testing as a service
development of fully automatic series testing systems
integration into production lines
process documentation and quality assurance

MACEAS – testing technology for hydrogen technologies

MACEAS combines many years of experience in special machine construction with specialized know-how in leak testing. For hydrogen applications, we develop testing systems that combine technical precision, process reliability and industrial automation.

Whether bipolar plate, stack component, hydrogen storage or H₂-carrying assembly: We develop the right test concept for your application.

Application examples

From Practice

Helium leak testing – bipolar plate

Technical specifications

Effective cycle time: 12 s
capacity: 300 parts/h
test gas: 10% helium / 90% air
Leakage rate: 4.8 ⋅ 10⁻⁵ mbar ⋅ l/s

Fully automatic or semi-automatic leak testing of bipolar plates made of metal or graphite with and without seals on the bipolar plate.

Leak testing of bipolar plates –
your reliable testing service for samples, prototypes and small series

The leak tightness of bipolar plates is crucial for the performance, durability and safety of fuel cells and electrolyzers. To ensure this, we offer you a specialized testing service that saves you having to set up your own testing facilities during the development process.

What we offer:

Testing of samples and prototypes: We test your first prototypes for leak tightness and help you to identify and rectify design or manufacturing weaknesses at an early stage.
Leak testing for small series: Even when producing smaller quantities, we ensure that every bipolar plate meets the high requirements for tightness and reliability.
State-of-the-art testing methods: We use the latest testing methods to simulate real operating conditions in order to detect and rule out even the smallest leaks.

Your benefits:

Cost efficiency: Save yourself the investment in expensive testing equipment for the time being and use our service to respond flexibly and cost-effectively to your testing requirements.
Fast results: We provide you with fast and accurate test results so you can continue your development and production processes without delays.
Expert knowledge: Benefit from our many years of experience and specialized know-how in the field of bipolar plate leak testing.

Why our testing service?

When developing new products or manufacturing small batches, setting up your own leak testing system is often uneconomical and time-consuming. Our service allows you to concentrate fully on your core competencies while we reliably take over the leak testing of your bipolar plates.

Whitepaper: Hydrogen in the future? Anything but simple.

What is necessary for a reliable evaluation of the economical production of metallic bipolar plates for fuel cells and electrolyzers? And how can corresponding manufacturing processes be scaled and standardized? Answers to these and many other questions are provided by the whitepaper “A Hydrogen Future? Far from Simple.” from Graebener®.

MACEAS made a significant contribution to the creation of the whitepaper and provides both the whitepaper and the process navigator for download.

To receive the whitepaper, please enter your email address in the field below. After clicking the sign-up link in the confirmation email, you will gain access to the whitepaper and agree that we may also inform you in the future by email about our products and services.

Request whitepaper

Tech Talk:
Leak testing of bipolar plates

Discover now
MACEAS systems on Hyfindr

Hyfindr is a new B2B marketplace for technical components, systems and services for the hydrogen and fuel cell industry. MACEAS is represented on Hyfindr with various systems.

What distinguishes MACEAS

Many years of experience in quality assurance, especially in leak testing

State-of-the-art testing technology
and technologies

Reliability and precision
are our top priority

Customized solutions for your individual requirements

Rely on our expertise and our commitment to the highest quality

Are you planning leak testing for bipolar plates, fuel cell components, electrolyzer parts, hydrogen pressure vessels or cryogenic hydrogen tanks? Please contact us. We will advise you on the suitable test method, the appropriate system concept and the possibilities of automation.

Daniel Schönbohm

Managing Director

Hydrogen Technology

Hydrogen & Energy Systems

Testing systems for fuel cells, electrolyzers, hydrogen storage and H₂ components

Testing systems for fuel cells, electrolyzers, hydrogen storage and H₂ components

Why leak testing is crucial in hydrogen technology

Why our testing service?

What we offer

Your benefits in the testing service

Good reasons for MACEAS

Quality assurance along the hydrogen value chain

MACEAS supports customers along different development and production phases:

MACEAS – testing technology for hydrogen technologies

Leak testing of bipolar plates – your reliable testing service for samples, prototypes and small series

What we offer:

Your benefits:

Why our testing service?

Whitepaper: Hydrogen in the future? Anything but simple.

Request whitepaper

Tech Talk: Leak testing of bipolar plates

Discover now MACEAS systems on Hyfindr

What distinguishes MACEAS

Leak testing of bipolar plates –
your reliable testing service for samples, prototypes and small series

Tech Talk:
Leak testing of bipolar plates

Discover now
MACEAS systems on Hyfindr