Helium Leak Testing Systems by VES

World-renowned helium leak detection expertise, with over 1,600 systems deployed globally for automotive, HVAC, clean energy and industrial manufacturing applications.

Precision Helium Leak Testing for Automotive, HVAC and Clean Energy Sectors

What Is Helium Leak Testing?

Helium Leak Testing Systems for Production Environments.

Helium leak testing is a highly sensitive method of detecting leaks in components, assemblies and production parts. Helium is used as a tracer gas because it is inert, non-toxic, light and detectable at very low leak rates.

In manufacturing environments, helium leak testing systems help verify product integrity, protect safety-critical components and support quality assurance across sectors such as HVAC leak testing systems, automotive, clean energy, hydrogen and medical manufacturing.

VES designs and builds helium leak testing systems around the product, required leak rate, production volume, cycle time and test method, helping manufacturers achieve reliable results in real production conditions.

helium-leak-testing-machine

Custom Leak Detection

Engineered for precision and reliability, our Custom Helium Leak Testing Machines deliver outstanding sensitivity, repeatability, and durability

optvol-helium-leak-testing

OptVol Leak Detection

OptVol is a compact, all-in-one helium leak testing solution. Capable of detecting leaks as small as 5.0e-06 mbarL/s,

Accuro Leak Testing

Accuro is a high-performance mass spectrometry leak testing system designed to work without a vacuum setup.

Comprehensive Helium Leak Testing Systems

Explore VES helium leak detection systems for production environments, from high-sensitivity hard vacuum chambers to accumulation, sniffer, spray and automated leak testing methods designed around the part, leak rate, cycle time and production process. For deeper technical background, read our helium leak testing guide.

Whether you're leak testing fuel tanks, HVAC parts, or medical devices, our technologies include hard vacuum systems, cost-effective accumulation testing, pinpoint sniff detection, and strategic spray methods. Each tailored for precision and reliability.

Helium Leak Detection
Leak Testing Methodologies

Cost-effective and chamber-free, accumulation testing uses helium as a tracer gas under atmospheric pressure. Ideal for detecting medium-to-small leaks with repeatable accuracy, it's a perfect upgrade from air-under-water and pressure decay methods.

Leak Rate Definition
Unit Conversion Tables

Best for large or complex parts, sniff testing locates helium leaks directly using a handheld or robot arm-held probe. It's ideal when pinpointing and repairing leaks is essential — especially when full chamber testing isn't practical.

Laws of Ideal Gas
OptVol Leak Detection

Designed for evacuated parts, helium spray testing strategically exposes components to helium to detect areas of potential ingress. A reliable choice for parts requiring absolute barrier integrity under vacuum conditions.

Leak Testing Brochure
Leak Testing Videos

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Engineered Testing Confidence – from concept to production.

Reducing Helium Cost and Waste

Helium is an effective tracer gas, but it is also a valuable resource. For manufacturers using helium leak testing systems at scale, gas cost, availability and sustainability can become important parts of the business case.

VES can support helium-efficient test strategies through system design, gas management and PURE helium recovery systems. PURE helps manufacturers recover, repurify and reuse helium from suitable leak testing processes, reducing waste while helping maintain test integrity.

For connected support, VES also provides calibration services and clean energy test expertise including hydrogen testing systems.

Frequently Asked Questions

Find quick answers to common questions about our helium leak testing systems, methods, and applications.

Helium is an ideal tracer gas due to its small atomic size, inert properties, and low natural atmospheric concentration (approx. 5.2 ppm). These characteristics allow for highly sensitive, quantifiable, and repeatable leak detection with minimal environmental impact.

HVAC systems must maintain airtight seals for refrigerant efficiency, safety, and environmental compliance. Helium testing allows for early detection of micro-leaks that could otherwise lead to performance loss or costly refrigerant loss over time.

Helium leak detection systems can identify leak rates as low as 1.0×10⁻⁸ mbar∙l/s, significantly outperforming pressure decay or bubble test methods. This makes them suitable for components where even the tiniest leaks can compromise safety or performance.

This depends on the component type and production volume. Common methods include:

  • Vacuum chamber testing – best for high sensitivity and automation.
  • Helium sniffing – ideal for pinpointing leak locations manually.

Helium accumulation – cost-effective when vacuum chambers aren't feasible.

While helium gas can be costly, systems like VES PURE helium recovery allow for recovery and purification of helium with >99% purity, drastically reducing long-term costs. PURE offers ROI in as little as 1.6 years depending on usage volume.

Yes. VES systems support manual to fully automated setups. They can operate as standalone units or be integrated inline with production lines—up to 100 parts/min depending on design.

Absolutely. Helium leak testing:

  • Reduces waste and rework
  • Supports type-approval for clean mobility (especially hydrogen and EVs)

Offers low carbon footprint solutions like the OptVol system

Leak rate thresholds vary by part and safety standard. For example, fuel tanks or battery housings may require <10⁻⁶ mbar∙l/s, while HVAC might allow higher. VES can help define these values based on application and legislation.

Leak rate is calculated using:

Q = (Δp × V) / Δt,
 where Δp is pressure difference, V is volume, and Δt is time. SI units express leak rate in mbar·l/s.

Yes. Conversion tables exist for:

  • mbar·l/s to cc/min or atm·cc/sec

pressure and volume units
 These help standardise specifications across global teams and suppliers.

Absolutely. F-Gas regulations in Europe and EPA rules in the U.S. require leak-tight systems to minimise greenhouse gas emissions. Helium leak detection helps manufacturers demonstrate compliance and avoid penalties.

The right helium leak testing system depends on the part design, leak rate threshold, production volume, cycle time and whether the test needs to locate a leak or confirm that the part is leak-tight. VES can specify hard vacuum, accumulation, sniffer, spray, manual, semi-automated or fully automated systems around the application.

Yes. VES designs helium leak testing systems for standalone use, semi-automated cells and fully integrated production lines. Systems can be configured around part handling, tooling, data capture, traceability and throughput requirements.

Speak to a Helium Leak Testing Specialist

Get personalised guidance for your leak testing challenges.


    VES Leak Detection Systems designed, manufactured and commissioned for leak testing hydrogen pressure vessels

    Customers

    Daikin Air Intelligence
    Mitsubishi Electric
    Marelli
    Plastic Omnium