Volumetric Fill Leak Testing (IP67 Leak Testing)

IP67 or IPXX leak testing (also known as Volumetric Fill or Metered Volume) is a non-destructive leak testing method used to detect leaks in a wide range of products, from medical devices and automotive components to sensitive military and defense applications. Volumetric fill testing is commonly used for IP67 (ingress protection) to ensure a product cannot ingress water or dust. It’s specifically used for leak testing sealed products or products that do not have a means of allowing air to be introduced to the inside of the product.

The key to the IP67 test method is the assumption that a sealed chamber, loaded with a device being tested without any leaks, will maintain its pressure.

The technique involves placing a sealed part into a chamber, then monitoring the change in pressure (or vacuum) over time that occurs inside the chamber. If the pressure inside of the chamber drops, it indicates air leaking into the product being tested.
 

How IP67 and Volumetric Fill Leak Testing Works

1. Loading the Component into a Chamber: The part being IP67 tested is loaded into a leak free chamber. The chamber lid is closed and sealed shut.
2. Pressurization: Chamber pressurization takes 3 steps.
   1.  Pre-pressurization: A precision pressure regulator pre-charges a volumetric device to the target pressure prior to the start of the test.
   2.  Pressurization: Upon cycle start (fill) the volumetric device releases its pressure into the test chamber.
   3.  Post pressurization Once pressure is released, the isolation valve closes to trap the pressure in the chamber.
3. Stabilization: The test pressure is allowed to stabilize which allows for stretching/cooling of the chamber and the device under test.
4. Decay Monitoring: After stabilization, the chamber pressure is monitored over a specific period. If a leak exists in the device under test, air escapes from the chamber into the device under test, causing a detectable drop in pressure in the chamber.

If the chamber pressure decays at a rate above a predefined IP67 reject threshold, the tested component is deemed defective.
As an industry leader in IP67 and Volumetric Fill leak testing. LeakMaster’s patented leak testers successfully test millions of sealed, IP67 products annually. Through years of experience and a customer-first mindset, we strive to make every application a success.

Key Benefits Metered Volume Leak Testing (IP67 Leak Testing)

• Perfect for sealed component leak testing (parts without a port or passageway to pressurize or apply a vacuum).
• High Sensitivity: This method is sensitive enough to detect small leaks, which is crucial in applications where even tiny leaks can compromise performance or safety.
• Non-Destructive: Does not alter or damage the component, making it ideal for sensitive or expensive parts.
• Simple and Fast: The process is relatively quick and easy to set up. Results are often available within a few seconds, depending on the size of the part being tested and the size of the leak that you are trying to detect.
• Versatile: Metered volume leak testing can be performed with a Pressure Decay, Vacuum Decay, or Differential Pressure Decay leak test circuit. This method is widely used across industries such as automotive electronics and consumer electronics such as phones or watches. It is also used in applications such as optics (scopes), electronics enclosures, sealed lighting assemblies, and pharmaceutical/ food packaging.
• Quantitative Results: Metered Volume provides numerical data, making it easy to determine the severity of leaks and to make precise decisions about part integrity.

Common IP67 Volumetric Fill Applications

• Automotive Industry: Engine control modules (ECM) sealed electronic sensors, cameras, and switches.
• Medical Devices: Diagnostic and drug delivery systems, surgical instruments, catheters, tubing sets and other fluid management equipment.
• Consumer Goods: Electronics, phones, smart watches, vacuum-sealed packages, or any components requiring an IP (ingress protection) rating.
• Military and Defense: Optics and scopes, GPS modules, sealed explosives and storage containers.

Volumetric fill and IP67 leak testing is a reliable, cost-effective method for detecting leaks in sealed products. Its non-destructive nature, coupled with its ability to provide quick, quantitative results, makes it a popular choice for quality control and assurance in manufacturing worldwide. Whether it’s ensuring the integrity of an automotive part or verifying the airtightness of a medical device, Volumetric fill decay testing offers a high level of precision and sensitivity that contributes significantly to product quality and safety.
 

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