Testing & inspection
End-of-line test benches and leak testing machines
Stop defects before dispatch. We build leak testing machines, end-of-line function testers and inspection stations with proper fixturing, sealing, sensing and data logging — so every part that ships has a recorded result.
At a glance
- Tests
- Leak, pressure, flow, electrical, function, dimensional
- Methods
- Air decay, pressure decay, mass flow, custom
- Data
- Serial-wise results, reports, MES export
- Timeline
- Indicative 8–14 weeks from design freeze
- Acceptance
- Repeatability with master parts, cycle time
Overview
A test is only as good as its fixture and its data
Most test failures in production are not instrument problems — they are sealing, fixturing, temperature and handling problems. A leak tester with a poor sealing nest produces false rejects; a function tester without data logging cannot prove what was tested.
We design the complete test station: part location and sealing, pneumatic or electrical connection, the test method and parameters, pass/fail logic, reject handling and data storage. The system is validated for repeatability with master parts before dispatch.
Test benches can stand alone at the end of a line or be integrated into it, with interlocks so untested or failed parts cannot move forward.
What we build
Testing systems we build
Leak testing machines
Air-decay and pressure-decay leak testing of castings, radiators, valves, housings and enclosures.
Battery pack & enclosure testing
Leak, insulation and functional test stations for EV battery packs, modules and enclosures.
End-of-line function testers
Electrical and functional testing of motors, pumps, controllers and assemblies.
Pressure & burst testing
Hydrostatic and pneumatic pressure test benches with safety enclosures.
Flow & performance rigs
Flow, pressure and performance testing of pumps, valves and fluid components.
Vision & dimensional inspection
Camera- and sensor-based checks for presence, orientation and critical dimensions.
Torque & force testing
Stations for measuring torque, force and displacement characteristics.
Marking & traceability
Part marking and code verification tied to test results.
Test rig upgrades
Data logging, new controls and new fixtures for existing test benches.
Technical
Test Benches & Leak Testing — applications, specifications and deliverables
The same three-part technical structure on every solution page, so engineering and procurement can compare scopes without reading marketing copy.
Applications
What it is applied to
- Leak testing of aluminium castings and housings
- EV battery pack and enclosure testing
- Radiator, condenser and heat-exchanger testing
- Motor and pump end-of-line testing
- Valve and fluid-component testing
- Appliance safety and functional testing
Not listed? Describe the operation — most scopes we quote are variations on these.
Typical specifications
What we engineer to
- Test type
- Air-decay or pressure-decay leak, function, flow, end-of-line performance
- Leak rate resolution
- Selected from your accept/reject limit and part volume
- Test pressure
- Set from the part specification; regulated and monitored
- Cycle time
- Typically 15–90 s including fill, settle, test and vent
- Sealing
- Part-specific sealing tooling with quick-change for variants
- Instrumentation
- Leak instrument, pressure transducers, flow meters, load cells
- Controls
- PLC/HMI with recipes per variant and limits under access control
- Traceability
- Per-part result logged with serial, limit and measured value
- Data export
- CSV, SQL or MES interface with retention plan agreed
- Validation
- Master-part and calibrated-leak checks; gauge study on request
Indicative ranges. Final specifications are fixed against your part and volume at design freeze.
Engineering deliverables
Documents you receive
- General arrangement (GA) drawing with footprint and utility points
- 3D model of the machine or station (native plus STEP/IGES)
- Bill of materials with makes, part numbers and bought-out list
- Electrical schematics, panel GA and I/O list
- Pneumatic and hydraulic circuit drawings with set pressures
- PLC, HMI, robot and vision program backups
- Operation and maintenance manual with SOPs and spares list
- FAT and SAT protocols with signed results
- Test specification with limits, settle and test times
- Master-part and calibrated-leak verification records
Programs and drawings are handed over, so your team is never dependent on us for a change.
Engineering scope
How each element is engineered
The design decisions behind the specification above.
| Test methods | Air decay, pressure decay, mass flow, electrical and functional tests as specified |
|---|---|
| Instruments | Established makes of leak testers, sensors and DAQ — or your approved list |
| Fixturing | Sealing nests, pneumatic connectors, part-specific adapters, quick change |
| Data | Serial-wise results and curves; export to CSV, SQL or MES |
| Validation | Master-part checks, repeatability study, cycle-time proving |
| Safety | Guarding and interlocks; pressure-rated components for pressure tests |
Handover
What you receive
Every test bench project closes with a documented handover — not just a machine on the floor.
- Test specification and method statement
- Fixture and station design
- Electrical, pneumatic and software documentation
- Validation report with master-part checks
- Data format and backup procedure
- Operator training and calibration schedule
Execution
How we execute a test bench
One project manager, stage gates you sign off, and no hand-offs between vendors.
Define
Test requirement, acceptance limits, part and cycle time.
→ Test specification
Engineer
Method, fixture, sealing, controls and data design.
→ Design freeze
Build
Station build, instrument integration and programming.
→ Build complete
Validate
Master-part trials, repeatability and cycle time.
→ FAT report
Install
Installation and interlocking with your line.
→ SAT
Support
Calibration schedule, training and support.
→ Handover
Applications
Where it is used
- Leak testing of aluminium castings and housings
- EV battery pack and enclosure testing
- Radiator, condenser and heat-exchanger testing
- Motor and pump end-of-line testing
- Valve and fluid-component testing
- Appliance safety and functional testing
Industries we serve
Why Mecwerx
Why manufacturers choose us for this
Fixture-first design
Sealing and location are engineered for reliable results and fewer false rejects.
Data you can defend
Serial-wise results support customer audits and warranty investigations.
Validated before dispatch
Repeatability is checked with master parts before the bench leaves our facility.
Integrated with the line
Interlocks ensure untested or failed parts cannot move forward.
Quotation checklist
What we need for an accurate test bench quote
Send what you have. Missing details are fine — we will fill the gaps during the technical discussion.
- Part drawing and material
- Test type and acceptance limits
- Test pressure or parameters, if known
- Cycle time and volume
- Number of variants
- Data and traceability requirements
- Customer or standard specifications that apply
Products
Test Benches & Leak Testing we build
Standard and custom-built products delivered under this solution line.
FAQ
Test Benches & Leak Testing: common questions
What is air-decay leak testing?
The part is pressurised with air, isolated, and the drop in pressure is measured over a set time. If the drop exceeds the limit derived from the allowed leak rate, the part is rejected. It is widely used for castings, housings, valves and enclosures.
Why does our leak tester give false rejects?
Common causes are poor sealing at the fixture, temperature differences between the part and the test air, short stabilisation times and incorrect limits. We review fixturing, parameters and environment to eliminate false rejects.
Can test results be linked to part serial numbers?
Yes. Results, curves and parameters can be stored against part serial numbers or QR codes and exported for audits and MES.
Do you build test benches for EV battery packs?
Yes — leak, insulation and functional test stations for packs, modules and enclosures, with appropriate safety measures.
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Learn moreStart a project
Hand over your production challenge.
Tell us what the line has to produce, where, and by when. We will come back with a scoped approach, a realistic timeline and the questions that matter — usually after a site visit or a drawing review.
- +91 85959 55435 · Mon–Sat, 09:00–18:00
- WhatsApp an engineer
- info@mecwerx.com
- Detailed RFQ with drawings (PDF, DWG, STEP)