The consequences of leakage in an electric vehicle are not equivalent to those in a conventional vehicle. Coolant ingress into a battery module can trigger thermal runaway. Moisture ingress into a high-voltage enclosure can cause insulation breakdown and create shock hazard.
As EV production volumes scale globally, manufacturers and their supply chains require leak testing solutions that combine detection sensitivity with production-line throughput, and that are supported by the calibration traceability and process documentation that regulated vehicle production demands.
Standards and Accreditation
Our instruments and calibration services are designed to support the quality and compliance requirements of EV manufacturers and their supply chains.
Furness Controls holds UKAS accreditation and operates in accordance with ISO/IEC 17025:2017 across our calibration laboratories in the UK, France, Germany, and the US. All calibrations are fully traceable to national standards.
Component |
Test Parameters |
Recommended Products |
|---|---|---|
EV battery cooling circuit |
Pressure decay leak test 2-4 bar test pressure |
|
EV battery enclosures |
Pressure decay leak test | Typical test pressures: vacuum to 2 bar Continuous leak testing option to assist final assembly |
|
Heat exchanger assembly (cooling) |
Pressure decay leak testing @ 2 bar < 2cc/min fail limit |
|
Vehicle lumbar support bladders |
Pressure decay leak testing @ 2 bar < 2cc/min fail limit |
|
Pneumatic/self-levelling suspension airbag |
Pressure decay testing @ 10 bar < 0.5 cc/min |
|
Pneumatic suspension control valves/valve blocks |
Test pressures 2 – 10 bar. Limit < 0.5 cc/min |
|
Windscreen/headlight washer system |
Test pressures circa 500 mBar < 2 cc/min fail limits |
|
Electronic control module casings. ECU/DME/Inverter/Motor control electronics |
Case leak test @ o.5 - 1 bar < 2cc/min Permeable membrane (goretex) breather flow rate 150 mBar < 5 cc/min |
|
TPMS (tyre pressure monitoring) validation/QA |
Variable pressure 0 – 3 bar |
|
Parking cameras |
Vacuum and up to 1 bar less than 2 cc/min |
Looking for a more specialised solution?
We design, manufacture, and calibrate all instruments in-house, with our headquarters in East Sussex and dedicated calibration laboratories in France and Germany. If your application falls outside standard parameters, our engineers can develop a bespoke instrument tailored to your exact test requirements - delivering a complete turnkey solution from specification through to calibration and commissioning.
Have a question, want to find out more, or ready to speak to an engineer?
Have a question, want to find out more, or ready to speak to an engineer? Our team has supported electric vehicle manufacturers with leak and pressure testing challenges as the sector has grown.
Get in touch below