The Pioneer of Modern Leak Testing

Multi-Channel Leak Testing Done Right

Let’s face it everybody wants to get more done with less. Whether we are talking staffing, robots, AI or automated assembly lines – the more you can do faster, the better. The same, of course goes for leak testing. As it’s our business, we know that for some (many) manufacturers, leak testing is a necessary but not so popular activity. It often happens at the end of the manufacturing process and can become a bottleneck.

Factory throughput is a major challenge facing production engineers and woe betide the quality control team that makes that challenge even harder. The leak testing bottleneck can be improved by adding more testers, but a a price or by finding a way to test several parts or assemblies at the same time. Multiple parts are often connected to a common test port using a manifold in the attempt to increase testing throughput.

The manifold approach to leak testing has two serious drawbacks.  First, the manifold and the parts themselves create a large volume.  The increased volume reduces sensitivity causing longer test times, which is precisely what multiple testing was trying to solve. Given what I just wrote a few sentences ago that doesn’t seem the smart solution does it? But wait, there’s more….

Because the parts are connected to one common air source, the tester has no way to identify which parts failed.  A failure in any part demands a second test.  This re-testing takes even more time.

Sprint mD Multi-Channel Testing Capabilities

Sprint mD for Medical Device ApplicationsUson has several leak testers that can deliver multi-channel concurrent testing, Optima vT, Vector and Sprint mD. Let’s look at the Sprint mD as it is the most economical and effectively serves the medical device market where high volume production of small parts and devices is common place. Sprint mD can be configured as a four-channel pressure decay tester with four independent sensors and test circuits contained in one compact machine.  Four parts are independently tested at the same time without a manifold.

Each part tested has its own bar graph and status window on Sprint’s large liquid crystal display.  The operator knows exactly which parts failed.  No re-testing.  Because the four test circuits are independent, the volume remains small and the test is much faster than a manifold-type test.

Using the Sprint mD is similar to running four testers at the same time.  But it’s better because Sprint costs so much less than four machines.

How it Works

Sprint mD Multi-Channel Leak Test Figure 1The Sprint mD tester works like this:

  • Product [P] is attached to the four test ports either manually or by automated machinery. (Figure 1)
  • The test is initiated by pressing Sprint mD’s start button or by remote input.
  • Sprint mD pressurizes the four parts with the fill valve [V1] then traps air in each separate test circuit between the product and the valve.
  • Trapped air pressure in each of the four test circuits is measured by an individual pressure sensor [S].
  • If any of the four parts fail, Sprint’s large gauge dial turns red and a signal is sent to the I/O port.  Sprint mD’s high definition display shows exactlySprint mD Fail Test which parts pass and which parts fail.  (Figure 2)
  • The Sprint mD display shows all four channels at the same time.  Each channel (test port) has its own bar graph and status indicator. 
  • The large color display is easy to read under varying lighting conditions showing the status during each test, the display indicates fill, stabilization, test and dump during the respective cycle period.
  • In an automated operation, the pass fail information is sent to SprintmD’s I/O port on the back of the machine.


This multi-channel tester is an extremely flexible machine with the ability leak test a broad range of products.  From small to large, rigid to flexible, Sprint mD is perfectly suited to the challenge of accurate testing that is both fast and affordable.  The Sprint mD can be used to test either multiple products or products that have multiple parts.

Other Sprint Models

Although you can use the four-channel machine to test fewer channels, if you don’t need all four channels, SprintmD is also available in two and three channel configurations.

Mass Flow

A Sprint mD’s four channel Sequential tester can test four parts using mass flow in series.  One mass flow transducer tests four parts one after the other for leakage, blockage, or for correct flow rate.


  • Extremely fast
  • 16 Programmable Inputs/Outputs
  • Local authentication, audit logs, test setup, statistics, real-time data, self-test diagnostics
  • Large 8.5” color touch screen LCD with a rich dashboard-style user interface
  • Tests large or small volume parts
  • Can use as a 1-4channel tester
  • Perfect for bench or automation
  • Small footprint (10 x 12 Inches)
  • 24-bit ADC for high-resolution pressure measurement
  • Easy to program and calibrate
  • Many available options!

Contact us for more information about the Sprint mD’s Multi-Channel leak testing capabilities or reach out to your local Uson Representative.

The Author

Joe Pustka, Director of Applications Engineering
Joe Pustka, Director of Applications Engineering
Multi-Channel Leak Testing

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