Leak and Flow Testing for Precision Components and Automotive Systems

Precision manufacturing and automotive supply chain testing demands the broadest range of leak test methods. Precision bearings need sub-0.1 kPa differential sensitivity. Vehicle refrigerator capillaries need volumetric flow measurement. Optical lens assemblies need 4-channel simultaneous airtightness for throughput. Figurtech covers the full range.

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Case: Precision Optical Lens Assembly — 4-Channel Simultaneous Testing

Instrument: LM 4-Channel Airtightness Tester
Customer: Optical and imaging component manufacturer, Xiamen
Fixture: 4-position precision aluminum tooling, white-surface test bench

Challenge

Precision lens modules for industrial and consumer imaging systems require 100% airtightness validation before assembly into housings. With four lens variants running on the same production station, single-channel testing would require four sequential cycles — exceeding available takt time.

Solution

The LM 4-channel tester runs all four channels simultaneously. Precision aluminum tooling holds each lens module in its test position. One operator loads four parts, initiates the cycle, and receives four independent OK/NG decisions simultaneously. The touchscreen data log captures per-channel test results with timestamps — full traceability at 4× the throughput of a single-channel system.

Result

• 4 independent pass/fail decisions per test cycle
• Per-channel data log with timestamps — SPC and traceability ready
• Precision aluminum tooling machined to lens-module geometry
• Deployed at imaging component production facility, ongoing volume production

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Case: Vehicle Refrigerator Capillary — Flow Measurement at 700 kPa

Instrument: LF Series Flow Tester
Connector: LT-KZ02 Stainless Claw External Clamp (50 bar rated)

Test Parameter	Value
Test Pressure	650–750 kPa
Flow Acceptance Window	3.42–3.58 L/min
Connector Rated Pressure	50 bar (5000 kPa)
Connector Cycle Life	≥ 500,000 cycles

Challenge

Vehicle refrigerator copper capillaries must meet a precise flow rate specification at operating pressure. A capillary that passes a standard pressure decay test may still have an internal diameter outside the manufacturing tolerance band — resulting in a flow rate that is too high or too low. Pressure testing alone cannot identify these defects.

Solution

The LF Series applies the specified test pressure and measures actual volumetric flow. Capillaries within the 3.42–3.58 L/min acceptance band pass; those outside are flagged regardless of pressure integrity. The LT-KZ02 stainless claw connector handles 700 kPa test pressure and maintains seal integrity across 500,000+ cycles.

Result

• Flow-based testing captures bore-diameter non-conformance invisible to pressure decay
• 3.42–3.58 L/min acceptance window maintained across full production batch
• LT-KZ02 connector cycle life matches production volume requirement without replacement

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Case: Switch Button Assembly — Multi-Channel Automotive Line

Instrument: LM 4-Channel / LG 2-Channel
Fixture: Pneumatic inner-expansion fixture

Challenge

Automotive switch and button panels contain 2 to 4 individual switch positions, each requiring sealed airtightness validation per IP specification. Testing one switch at a time creates a bottleneck in the assembly process.

Solution

The LM 4-channel system tests four switch positions simultaneously. For 2-switch panels, the LG 2-channel auto-regulating tester covers both positions in a single cycle. Pneumatic inner-expansion connectors seal each switch port automatically when the fixture closes.

Result

• 4-switch panels tested in a single cycle — no throughput penalty
• Per-switch OK/NG decision with data log
• Pneumatic fixture enables unmanned cycle operation when integrated with line PLC

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Recommended Configuration — Precision & Automotive

Application	Instrument	Connector
Precision bearing (< 0.1 kPa sensitivity)	LD Series	LT-D02 (external clamp over bearing OD)
Capillary flow (650–750 kPa)	LF Series	LT-KZ02 (stainless, 50 bar)
Lens assembly (4-channel)	LM 4-Channel	Custom precision aluminum tooling
Switch/button panel (×4)	LM 4-Channel	LT-Q01 (pneumatic inner expansion)
Vehicle-mount controller (13–150 kPa)	LY Series	LT-D02 (external clamp)