Body Armor: Ballistic material for bulletproof vests sealed in protective packaging. Traditional test method of packaging using bubble-immersion leak testing was messy, slow and lacked the sensitivity needed to be truly effective. Water ingress into a defective package would ultimately render the contents (ballistic material) unusable and need to be scrapped/discarded. 

Key requirements:

  • Detect leaks to prevent water ingress into product packaging
  • Current method was a time consuming destructive process and required drying of the product after testing
  • Ability to detect gross leaks as well as small pinhole leaks
  • Test multiple product sizes and configurations
  • Limited equipment budget


Our custom solution incorporates the Force Decay leak test method with dual vacuum chambers. Force Decay methodology allows for non-destructive leak testing with the ability to identify both gross leaks as well as fine leaks.

  • Custom engineered system using standard leak testing platform
  • Dual chamber test system with an integrated force gauge in each chamber
  • Vacuum pump used to inflate the product
  • Various inserts to accommodate various product sizes
  • Serial interface to customer data logging system