Improve Speed & Accuracy of Battery Pack Leak Testing

A high quality, repeatable leak test is crucial for high volume EV battery production. Even a small leak under the electrical headers or cooling ports could allow contamination or condensation into the battery pack itself, resulting in catastrophic damage to the most expensive component on any EV. 

The electrical header connections mounted on EV batteries are generally brightly colored, glass filled polymers. Electrical header port sealing requirements have presented a significant challenge for EV engineers trying to achieve a leak tight seal with consistent compression around the port perimeter, particularly where small radius corners are present. While traditional o-ring seals are designed to effectively seal circular openings, EV battery pack electric header connections are often square, rectangular, or oval. 

To overcome this challenge, FasTest partnered with EV industry leaders to create a superior sealing, longer-lasting solution. Our new BEV family of leak test connectors incorporate a proprietary actuation and seal design that provides a consistent seal around the entire perimeter of non-circular ports, in addition to the durability, accuracy, and consistency demanded by engineers working on high volume EV production.  

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Please complete this form and a FasTest representative will be in contact with you. 

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Identify & Eliminate Leaks

Ensure all connection ports on battery are sealed and leak-tight to avoid the risk of condensation contamination to the battery cell. 

Designs for Automation

Automation friendly and customizable to any electrical header connection. Tailored connection tools to fit your battery. 

Improve Quality & Reduce Warranty Claims

Warranty claims are inherently expensive, especially when they involve an engine or battery. Precision engineered tools provide the highest quality connection and seal for accurate testing.

Manual Hand-Operated Connectors for Battery Pack Leak Testing

BEVM

Manual Connections to BEV Electrical Headers

VDAM

Manual Connections to VDA Ports

DGVM

Manual Connections to DGV Ports

Pneumatic Connectors for Automated Battery Pack Leak Testing

BEVP

Automated Connections to BEV Electrical Headers

VDAP

Automated Connections to VDA Ports

DGVP

Automated Connections to DGV Ports

Why FasTest for Battery Pack Leak Testing

Accurate Connection & Sealing

Precision engineered tools provide the highest quality connection and seal for accurate testing.

Reduce Repetitive Motion Injuries

Easy-to-use one hand operation, eliminate the painful twisting motions of standard fittings.

Safely Connect in Seconds

FasTest’s ergonomic tools instantly attach to ports and threads - no wrenches, thread tape, or sealants for a leak-tight seal. 

Safety First

Multiple safety features are included in every tool, including pressure assisted sealing technology.

Durable Connection Tools

Engineered for precision and durability to withstand rigorous testing environments.

Quality Tools, Quality Tests

Engineered for the highest quality connection and seal. Reduce False Failures caused at the connection points.

Trusted by Industry Leaders

Connection Tools Designed for Your Electric Vehicle Battery

FasTest has connection tools to outfit your entire battery with BEV electrical header leak test connectors. Our new BEV Series of leak test connectors incorporate a proprietary actuation and seal design that provides a consistent seal around the entire perimeter of non-circular ports. 

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Automate Your Leak Test Process with
ICON™ Intelligent Tools.

ICON™ is a process automation enabling technology engineered to enhance and maximize our customer’s testing process. 

  • Verify safe connections and reliable sealing.
  • Confirm step completion and set handshake points.

Integrating sensing and real-time data output into FasTest’s industry-leading connection tools. ICON™ puts the power in the hands of users to run smarter, safer, and faster tests. Whether you're making a manual connection or integrating automation, ICON™ technology has a connection solution for you.

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Related Vehicle System Applications

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Motors and Inverter Leak Testing

Connection tools for leak testing motors, inverters and coolant lines for both the electric vehicle and internal combustion engine markets.

Automotive Vehicle Systems

Connection tools for all your automotive leak testing and fluid transfer needs.

Contact a Battery Pack Connection Expert