Micro Application Leak Tester (MALT)

Recent times have seen progressive miniaturisation of devices. In some, it is critical that small
parts are leak proof and their production demands quality assurance for leak characteristics.
Examples are in small medical devices e.g. small drug dosing pumps, swallowable cameras,
diagnostic cartridges, lab on a chip devices, and medical vials. Non-medical applications
include in-tyre pressure sensors, electrical sensors and hermetically sealed parts. Existing
solutions are bulky, imprecise, or very expensive.
TQC developed a pre-prototype high-precision compact low cost Micro Application Leak
Testing module (MALT). The MALT is designed to minimise internal volumes below one
tenth of comparable instruments.
The MALT module uses differential pressure decay and can detect leaks by an order of
magnitude more sensitively than other pressure decay leak test instruments. TQC’s engineers
achieved this at a lower unit cost than existing solutions. Bespoke versions of the prototype
are successfully deployed in two distinct industrial assembly and leak testing applications,
validating the proof of concept.
The challenge remains to convert the initial prototype into a general purpose micro
applications leak test unit, and to enhance its capabilities for a broader range of applications.
Further developments are:
• create pneumatic micro circuitry and control for leak testing hermetically sealed parts
• build a vacuum micro-leak tester variant
• integrate a shock filling function for testing semi-flexible parts
• include functions to automatically calculate the test volume and set the test pressure
• redesign the electronics to SMT to further reduce the size and production costs
• enhance the user-interface and communications software so that MALT becomes an Internet
of Things device accessible remotely and by Cloud services
• ensure regulatory compliance for validation to FDA approval standards, IP rating enclosure
rating enclosure and ATEX rated for use in hazardous areas