Precisely detect the smallest leaks:
fast, objective, and fully automated.
MACEAS develops custom helium leak testing systems for components with particularly high requirements for tightness, process reliability, and production output. Testing methods, sealing, part handling, and evaluation are precisely matched to the component, leak rate limit, and cycle time.
Highest Measurement Accuracy
Short Cycle Times
Reliable Processes
The result: a custom testing system that consistently combines precision and productivity.
... and have your testing task evaluated
Advantages in Serial Production
Reliably detect
the smallest leaks
Helium enables the reliable detection of very low leak rates, ensuring safety for particularly demanding or sensitive components.
Obtain objective test results
The test provides objective measured values and enables clear pass/fail decisions based on clearly defined criteria.
Realize short cycle times
Optimized testing sequences, adapted pump technology, and multi-chamber concepts allow for integration even into fast serial processes.
Fully automate testing processes
From component feeding and testing to evaluation, sorting, and reject handling, the entire process can be automated.
Test without water
and drying
Since no water is required as a testing medium, the subsequent drying of the components is eliminated.
Typical Components and Applications
Bipolar plates and electrolyzer components
external leaks and cross-leaks between media channels
Battery cells and components as well as battery cooling elements (cooling plates)
detect very small leaks before assembly or filling
Fuel, cooling, and pressure systems
reproducibly test safety-critical tightness in series production
Comparison of MACEAS Testing Methods
| Kriterium | Helium-Dichtheitsprüfung | Ultraschall-Dichtheitsprüfung im Wasserbad | Elektrolyt-Dichtheitsprüfung | Druckabfallprüfung |
|---|---|---|---|---|
| Besonders geeignet für | Sehr kleine Grenzleckraten und quantitative Serienprüfung | Erkennung und direkte Lokalisierung von Leckstellen | Befüllte und verschlossene Batteriezellen | Mittlere bis größere Grenzleckraten und Serienprüfungen |
| Prüfzeitpunkt | Komponenten- und Baugruppenfertigung | Bei druckbeaufschlagbaren, für das Wasserbad geeigneten Bauteilen | Nach der Befüllung und dem Versiegeln der Zelle | Komponenten- und Baugruppenfertigung |
| Leckstelle lokalisierbar | Ja, mittels Helium-Schnüffelprüfung | Ja | In der Regel nicht unmittelbar | Nein |
| Wasserbad oder Trocknung erforderlich | Nein | Ja | Nein | Nein |
| Besondere Stärke | Höchste Empfindlichkeit und objektiver Leckratenwert | Anschauliche Leckageortung | Prüfung mit dem tatsächlich austretenden Elektrolyt | Wirtschaftlich und gut automatisierbar |
When pressure decay/differential pressure testing reaches its limits
Many manufacturers already test their components using pressure decay or differential pressure. The method is economical, can be automated, and is perfectly sufficient for numerous serial applications.
However, for very small permissible leak rates, the pressure change to be measured is so low that it is significantly influenced by temperature, component volume, or deformations. At this point at the latest, a switch to helium leak testing becomes necessary.
Helium enables a much higher detection sensitivity and delivers stable, reproducible measurement results even with demanding leak rate limits.
The smaller the permissible leak rate, the more decisive the helium testing method becomes.
Application Examples from Our Practice
Helium Leak Testing for Bipolar Plates
In bipolar plates, hydrogen, air, and cooling channels must remain permanently separated from each other. Even the smallest external leaks or internal crossovers can impair the efficiency, safety, and service life of the fuel cell.
MACEAS tests monopolar and individual plates as well as fully assembled bipolar plates – automated, reproducible, and with short cycle times.
Practical Example
Bipolar Plates
Which leaks are tested?
The testing task is not limited to a simple external leak check. It is also crucial that the individual media circuits within the bipolar plate remain reliably separated from each other.
Specifically tested are:
- the cooling channel against H₂, O₂, and the exterior,
- O₂ against H₂ and the exterior,
- H₂ against the exterior,
This allows both external leaks and internal crossovers between the media circuits to be detected. The test is suitable for monopolar and individual plates as well as fully assembled bipolar plates.
How does the test work?
The test parts are positioned in the test chamber via defined centering points. The chamber is then closed and the helium leak test is performed. After completion of the three measurements, the chamber opens again and the tested parts can be removed or transported further automatically.
Up to two components can be tested simultaneously per test module. Each test chamber can be equipped with its own pump station and mass spectrometer.
This clearly shows that it is not just a measuring device, but a complete system and testing concept including:
- component-specific fixture,
- precise positioning and clamping,
- test chamber including component-specific sealing,
- vacuum technology,
- helium mass spectrometer,
- control and evaluation.
How can the system be scaled?
The system concept is modular. For prototypes and small quantities, a main module to be loaded manually can be used initially. As production volumes increase, the system can be expanded with additional test modules as well as automated feeding and handling components.
The following performance levels can be achieved, although they are heavily dependent on requirements and design; rough orientation:
- from about 150 components per hour in the smallest configuration,
- up to 400 components per hour with manual loading,
- up to about 700 components per hour with fully automated part handling.
Through parallel test modules, the system can be scaled from prototype testing to automated mass production.
What automation options are possible?
Helium testing can be integrated step-by-step or fully into an automated production process. MACEAS lists the following as expansions:
- conveyor technology for feeding and discharge,
- automated handling for inserting and removing components,
- vision systems for position detection,
- automatic reject storage,
- rework stations,
- laser marking,
This allows testing, component handling, marking, and pass/fail sorting to be connected in a continuous process.
Setup and Maintenance
Reliably Separate Three Media Circuits
From Individual Plates to Mass Production
Individual plates and monopolar plates as well as assembled bipolar plates can be tested. The modular system concept can be expanded from a manually loaded prototype solution to a fully automated serial system.
Short Cycle Times through Parallelization and Automation
Two components can be tested simultaneously per test module. Additional modules, automated component handling, conveyor technology, and automatic reject sorting enable high throughputs and full integration into production.
Helium Testing Method
in Vacuum or Atmosphere?
Vacuum Testing
For particularly low leak rate limits and highest detection sensitivity.
Vacuum testing is suitable for particularly small permissible leak rates and the highest requirements for detection sensitivity.
Typical advantages:
- very high measurement accuracy,
- short testing times with appropriate system design,
- objective integral testing of the entire component,
- ideal for safety- and function-critical applications.
Typical working range of the testing system:
10⁻³ to 10⁻⁷ mbar · l/s
Atmospheric Testing and Helium Sniffer Testing
For medium leak rates, simplified system concepts, and economical serial processes.
Atmospheric testing does not require an evacuated test chamber. The component, pressurized with helium, is tested under ambient pressure. A sniffer probe detects escaping helium and, in addition to detecting a leak, also allows for its targeted localization. The probe can be guided manually or automatically along the relevant test areas.
The method is particularly suitable for applications where extremely low leak rate limits do not need to be detected.
Typical advantages:
- simplified system design without a vacuum chamber,
- testing at atmospheric pressure,
- detection and localization of leaks,
- can be performed manually or automatically,
- easy to integrate into economical serial processes,
- suitable for defined medium leak rate ranges.
Typical working range of the testing system:
10⁻² to 10⁻⁴ mbar · l/s
Which method is suitable depends on the leak rate limit, test pressure, geometry, and cycle time.
From the Task Definition
to the Finished Testing System
MACEAS considers not only the measurement but the complete serial process: from the testing tool and part handling to evaluation and integration.
Which leak test
fits your application?
Not every leak testing task requires helium. The component, leak rate limit, testing time, cycle time, and degree of automation are decisive.
MACEAS evaluates your requirements in a technology-neutral manner and develops the technically and economically suitable testing concept from them.
... and discuss your requirements with us
Frequently Asked Questions
Application and Suitability
How does a helium leak test work?
The component to be tested is pressurized with helium or surrounded by helium. If there is a leak in the component, the gas escapes through or enters the component through even the smallest leak points.
A highly sensitive mass spectrometer detects the escaping or entering helium and determines the leak rate. This allows for an objective and integral determination of whether the component meets the specified tightness requirements.
Since helium has very small atoms, is non-toxic as a noble gas, and can be reliably detected, it is particularly suitable for testing the smallest leaks.
When is a helium leak test useful?
What is the difference between helium and ultrasonic leak testing?
Which components can be tested with helium?
Is helium leak testing non-destructive?
Measurement and Testing Process
How sensitive is a helium leak test?
Vacuum or atmosphere – which method is more suitable?
Vacuum testing is suitable for particularly small leak rate limits and the highest requirements for detection sensitivity. Testing under atmospheric conditions is often the more economical solution for larger permissible leak rates and allows for simplified system concepts. This also includes helium sniffer testing, where escaping helium is detected with a manually or automatically guided sniffer probe and the leak point is specifically localized. Crucial for the choice of method are primarily the component, the required leak rate limit, the cycle time, and the testing goal.
Can leaks be localized?
Can the test be automated?
Can different component variants be tested?
Yes. Through interchangeable testing tools, adaptable fixtures, and stored testing programs, a system can be designed for several component variants.
How can the cycle time be reduced?
System and Economic Efficiency
How much does a helium leak testing system cost?
Can helium be recovered after the test?
Yes. Depending on the system concept, helium can be collected, processed, and reused. Especially with high quantities and/or large volumes, gas consumption and ongoing operating costs can be reduced as a result.
Managing Director
Have your testing task evaluated
Whether it’s an initial feasibility test, small series, or automated testing system: we develop the right entry point for your testing task.
Use our testing service without investing in your own system or get advice on a customized solution for your series production.