Fluid & Air Leak Detection Systems
Accurate fluid and air leak detection systems engineered for reliable, repeatable testing.
Fluid & Air Leak Detection Systems
Curtis Assemble & Test Ltd design and manufacture bespoke leak detection systems for both fluid and air applications. Our solutions are engineered to accurately detect and quantify internal and external leaks across sealing faces, valves, and precision components, helping manufacturers ensure product integrity, safety, and compliance.
With decades of experience in leak testing and automated inspection, CAT systems combine proven testing methods with robust mechanical design and intelligent control. Each system is tailored to your component, test medium, cycle time, and leak rate requirements, delivering reliable and repeatable results across development, validation, and production environments.
ADVANCED LEAK DETECTION TECHNIQUES
Our leak detection systems utilise a range of proven techniques, selected and configured based on the application, component design, and required sensitivity.
Pressure-based methods, including pressure decay and pressure rise testing, are widely used to calculate leak rates by monitoring pressure change over time under controlled conditions. Where appropriate, calibrated flow measurement is used to directly quantify leak rates with a high degree of accuracy.
For applications where forming a seal is difficult or impractical, CAT systems can incorporate vision-based leak detection. Using carefully selected lighting and optics, external leak paths can be identified and assessed, providing an effective solution for complex or open components.
LEAK DETECTION SYSTEM PERFORMANCE OVERVIEW
CAT leak detection systems are designed to operate reliably across a wide range of components, test media, and operating conditions. Each system is configured to deliver stable, repeatable results while accommodating the specific sensitivity, cycle time, and acceptance criteria required by the application.
Flexible control of pressure, temperature, and measurement methods allows systems to be adapted for both high-sensitivity leak detection and higher-throughput testing. Multiple evaluation techniques can be applied within a single system, ensuring accurate assessment of different component types while maintaining operator safety and consistent process performance.
Proven Leak Detection Methods
CAT systems can be configured using the most appropriate leak detection technology for the component, cycle time, and sensitivity required.
- Pressure Change Testing – Detects leaks by monitoring pressure decay or pressure rise over time within sealed components.
- Flow Rate Measurement – Measures air or fluid flow to identify leakage paths and quantify leak rates with statistically proven repeatability.
- Mass Flow Testing – High-sensitivity testing for small leak rates and precision components.
- Vision-Based Leak Detection – Camera systems used to verify bubbles, fluid escape points, seal presence, or assembly condition during testing.
- Multi-Stage Test Sequences – Combines fill, stabilisation, test, and reject logic for complex assemblies.
FLUID & AIR LEAK DETECTION SYSTEM CAPABILITIES
⚙️ Test pressure: Hydraulic up to 3000 bar, air 250 bar supporting high-pressure fluid and air leak testing applications
⚙️ Temperature range: Ambient to 60°C, with higher temperature options available depending on test requirements
⚙️ Leak rate measurement: From 0.01 cc/min up to 20 cc/sec and higher
⚙️ Cycle time: From 10 seconds, configurable to balance accuracy and throughput
⚙️ Pressure change methods: Pressure decay and pressure rise leak testing for accurate leak rate calculation
⚙️ Flow measurement: Calibrated flow meters for direct quantification of leak rates where applicable
⚙️ Evaluation criteria: Pressure change over time, timed pressure drop, measured flow, and blob growth
⚙️ Measurement media: Air, hydraulic oil, calibration fluid, and water
⚙️ Internal leak detection: Identification and measurement of leaks across valves, seals, and internal interfaces
⚙️ External leak detection: Vision-based inspection to identify external leak paths where sealing is impractical
⚙️ System configuration: Bespoke system layouts tailored to component type, leak rate, medium, and cycle time
Our fluid and air leak detection systems are trusted by manufacturers to deliver accurate, repeatable results across a wide range of applications. Each solution is engineered to meet your specific component, test method, and performance requirements.
COMMON APPLICATIONS
Fluid and air leak detection plays a critical role across industries where safety, reliability, and product integrity cannot be compromised. Accurate detection and quantification of leaks is essential to ensure performance, compliance, and long-term reliability.
Typical applications include:
Hydraulic Components
& Valves
Leak detection systems are used to verify sealing integrity in hydraulic valves, manifolds, and components, ensuring reliable performance under high-pressure operating conditions.
Pneumatic Systems
& Air Circuits
Air leak detection is used to identify and quantify leaks in pneumatic systems, helping maintain efficiency, reduce energy loss, and ensure consistent system performance.
Sealing Interfaces
& Mating Faces
Leak detection systems assess sealing faces, joints, and interfaces to verify integrity where even minimal leakage could impact safety or product performance
Safety-Critical &
High-Pressure Applications
In safety-critical applications, leak detection ensures components meet strict acceptance criteria before deployment, reducing risk and supporting regulatory compliance.
Prototype &
Pre-Production Testing
Leak detection is used during prototype development and pre-production testing to validate designs, refine sealing methods, and confirm repeatable performance.
Components Where
Sealing Is Difficult
Vision-based leak detection supports applications where conventional sealing methods are impractical, enabling identification of external leak paths using optical inspection.
Industries We Support
- Automotive – leak testing of fuel systems, air circuits, valves, and sealed assemblies.
- Aerospace – precision leak detection for critical pneumatic and fluid components.
- Medical Devices – integrity testing of sealed products where reliability and compliance are essential.
- Consumer Products & Electronics – leak and seal verification for enclosures, housings, and assembled products.
WHAT WE CAN DELIVER
Bespoke fluid and air leak detection systems tailored to your components
Accurate measurement of internal and external leak rates
Multiple leak detection methods, including pressure decay, pressure rise, and flow measurement
Vision-based leak detection for applications where sealing is impractical
Flexible cycle times to balance sensitivity and throughput
Support for a wide range of test media and pressure ranges
Reliable, repeatable testing to meet defined acceptance criteria
Integration into development, validation, or production test environments
Looking for an accurate and reliable fluid or air leak detection solution?
Our engineers will help define the right leak detection system to meet your testing requirements.
Talk to our engineering team, we’ll help define the right leak detection solution for your application.
Why Choose CAT?
☑️ Bespoke Leak Detection Solutions
Each system is engineered around your component geometry, test medium, leak rate, and acceptance criteria.
☑️ Accurate, Repeatable Measurement
Proven techniques deliver reliable leak detection results across repeated test cycles.
☑️ Multiple Detection Methods
Pressure decay, pressure rise, flow measurement, and vision-based inspection to suit different applications.
☑️ High-Pressure & Low-Leak Capability
Systems designed to handle demanding pressure ranges and very low leak rates.
☑️ Flexible Test Configuration
Cycle times, test methods, and evaluation criteria configured to balance sensitivity and throughput.
☑️ Proven Engineering Experience
Decades of experience delivering leak detection systems across a wide range of industries.
Real-World Performance, Real-World Trust
Looking for a trusted partner to deliver your
fluid or air leak detection system?
Our engineers will design and manufacture a bespoke leak detection solution tailored to your testing requirements.