Automotive & New Energy Leak Testing Solutions
Automotive & New Energy
Leak Testing for EV Battery Packs, Motor Housings & Automotive Assemblies
As electric vehicles replace combustion powertrains, sealing requirements have intensified. A failed seal on a battery tray means coolant intrusion, thermal runaway risk, and field recalls. Figurtech supplies the multi-channel, high-throughput leak test systems that Tier 1 automotive and new energy manufacturers rely on to validate every unit before it leaves the line.
The Manufacturing Challenge
Automotive and EV components combine large internal volumes, complex geometries, and tight leak specifications — often tested under high pressure or with aggressive media. Production cycles are short (sub-30 second targets), fixtures handle multiple variants, and every result must be traceable to a serial number for warranty and quality system compliance.
- EV battery trays and liquid-cooling plates: large volume, low allowable leak rate, coolant-side pressure test
- Die-cast motor housings and gearbox covers: complex cavity geometry, multi-point seal validation
- Automotive sensor housings, ECU enclosures, and on-board electronics: IP-rated sealing, high-volume inline testing
- Hydraulic and pneumatic connectors, valves, and fittings: direct high-pressure test up to 4 MPa
Recommended Instruments
| Series | Best for | Key capability |
|---|---|---|
| LM Series | Die-cast trays, multi-part pallets | 2–4 channel simultaneous, independent thresholds, per-channel data log |
| LY Series | Battery trays, sensor housings, ECU covers | 0–1200 kPa, 4-stage auto cycle, ≤20 s, PLC-ready |
| LG Series | Multi-variant lines, switch button assemblies | Electronic auto-regulation, multi-step programs, 2-channel |
| LE Series | Robotic cells, unmanned cabinet stations | Compact embedded module, ATEX-ready, full fieldbus integration |
Typical Applications
- EV battery tray sealing: 4-channel LM system, 23-second cycle, PLC-integrated with barcode scan — validates every tray before coolant fill
- Die-cast motor housing: Simultaneous 4-point test on complex cavity geometry, direct pressure up to 500 kPa
- Automotive sensor housing (IP67): LY inline station, differential pressure cross-check, 100% production coverage
- Switch buttons and actuator assemblies: LG 2-channel, auto-regulated multi-step program, multi-variant without changeover
- High-pressure hydraulic fittings: LY-M-V1000, direct pressure up to 1200 kPa, production-line ready
Why Figurtech for Automotive?
- Production-proven cycle times: Systems delivered and running at 23-second EV tray lines — not lab benchmarks
- Full MES traceability: Per-unit serial number logging, SPC data export, barcode scan integration as standard
- PLC and fieldbus integration: RS-232/485, Ethernet, and digital I/O — works with Siemens, Mitsubishi, Fanuc, and others
- Fixture engineering included: Custom multi-port fixtures designed and validated against calibrated standard leaks before delivery
- 12-month warranty + technical support: Dedicated application engineers, remote diagnostics, on-site commissioning available
Ready to validate your sealing process? Contact our application engineers with your part drawing, leak specification, and cycle time target.
Request an Engineering Evaluation →