When standard connectors don’t fit your application, FasTest’s custom engineering team designs the solution from scratch—custom leak test fixtures, custom leak test systems, and custom connector designs built to your exact specifications.
Not every sealing challenge can be solved with an off-the-shelf connector. Non-standard port geometries, tight clearance envelopes, unusual sealing surfaces, extreme pressures, aggressive media, or unique automation requirements all demand a purpose-built approach. That’s where FasTest’s custom engineering team excels.
With thousands of custom applications completed across automotive, aerospace, HVAC-R, compressed gas, medical, fluid power, and appliance industries, FasTest has the design experience, manufacturing capability, and application knowledge to solve sealing challenges that other suppliers walk away from. Whether you need a single custom connector design for a unique port, a complete set of custom leak test fixtures for a new production line, or a fully integrated custom leak test system with automation and data acquisition, FasTest engineers will work with you from concept through production-ready delivery.
The result: a solution that seals consistently, connects quickly, and performs reliably—because it was engineered specifically for your application, not adapted from something designed for someone else’s.
Below are some examples of process improvements we have provided to our customers.
Many manufacturers don’t start looking for custom leak test solutions until they’ve exhausted standard options and are dealing with the consequences. If any of the following sound familiar, it’s time to talk to FasTest’s custom engineering team:
If you’re dealing with any of these challenges, FasTest’s custom engineering team has almost certainly solved something similar. Submit an Application Evaluation to get started.
FasTest’s custom engineering capabilities span a wide range of complexity. Here’s what we can build for you:
When no standard FasTest connector fits your port, our engineers design a purpose-built connector from scratch. Custom connector design projects typically involve unique sealing geometries (non-circular ports, irregular flanges, proprietary thread forms), modified standard connectors adapted for specific clearance, pressure, or media requirements, multi-seal connectors that address several sealing surfaces in a single connection, and connectors optimized for one-handed operation in tight or awkward station positions. Every custom connector design includes full engineering drawings, material specifications, and validation testing before delivery.
Custom leak test fixtures go beyond individual connectors to address the entire test station interface. A typical custom fixture project includes mounting plates and adapter assemblies that position multiple connectors precisely relative to the part being tested, multi-port fixture plates that seal several connection points simultaneously in a single operator motion, ergonomic fixture designs that reduce operator reach, force, and cycle time, integration with existing test station frames, nesting fixtures, or automated part handling systems, and accommodations for gauges, sensors, data ports, and pneumatic/hydraulic supply lines. FasTest custom leak test fixtures are designed for production durability, with maintenance-friendly construction and readily available replacement seal kits.
For the most demanding applications, FasTest designs and delivers complete custom leak test systems—fully integrated packages that include everything needed to perform a specific test sequence. A custom leak test system from FasTest may include custom connectors and fixtures for all connection points on the part, pre-built hose assemblies and manifolds sized for optimal flow and minimal pressure drop, integrated ICON™ technology with SURE SEAL™ confirmation on critical connections, multi-station configurations for parallel testing or sequential multi-step test processes, data acquisition integration for seal confirmation, pressure monitoring, and traceability, and complete documentation including operating instructions, maintenance schedules, and spare parts lists. Custom leak test systems are delivered production-ready and validated as a complete assembly.
Not every custom project requires a ground-up design. In many cases, FasTest can modify a standard connector to meet your requirements—changing seal materials, adjusting dimensions, adding or removing features, or adapting the mounting interface. Modified standard products typically have shorter lead times and lower tooling costs than fully custom designs while still solving the application challenge.
Start by submitting your application details to fastsales@fastestinc.com - port drawings, CAD models, sealing surface specifications, test pressures, media, cycle time requirements, clearance constraints, and any photos or descriptions of current tooling problems. You can submit through the Application Evaluation form on our website, email drawings directly to your FasTest contact, or work through your local distributor. The more detail you provide upfront, the faster we can assess your challenge.
Every custom solution is tested against your specified requirements before shipment. For custom leak test fixtures and systems, this includes assembly-level validation to verify that all components work together as designed—seal integrity, flow performance, ergonomic function, and automation integration.
Your custom solution is manufactured, assembled, inspected, and shipped with complete documentation—operating instructions, maintenance guides, and recommended spare parts lists. For ongoing production needs, FasTest maintains your custom design on file for repeat orders and replacement parts.
FasTest provides technical support, maintenance parts, and design updates for the life of your custom solution. As your product or process evolves, our engineers can modify and update the design to keep pace.
Plenty of companies claim custom capability. Here’s what actually differentiates FasTest:
Many manufacturers default to building custom test tooling internally. Here’s how that approach compares to partnering with FasTest:
| In-House Custom Tooling | FasTest Custom Solution | |
|---|---|---|
| Design Expertise | General-purpose mechanical engineers designing sealing tools as a side project | Dedicated sealing connection engineers with thousands of custom applications |
| Seal Performance | Trial-and-error approach to seal material, geometry, and clamping force | Engineered seal design based on deep application experience and validated testing |
| False Failure Rate | Often high — inconsistent seals are the leading cause | Low — SURE SEAL™ confirmation eliminates operator uncertainty |
| Time to Production | Weeks to months of iteration, often with multiple redesigns | Streamlined process: evaluation → design → prototype → validated delivery |
| Ergonomics | Afterthought — designed for function, not operator comfort | Core design requirement — one-handed operation, minimal force |
| Maintenance & Spares | One-off parts; replacements require re-fabrication | Documented spare parts lists; reorder from FasTest directly |
| Scalability | Difficult to replicate across stations or plants | Design on file for repeat orders; consistent across all locations |
| Ongoing Support | Internal engineering team must maintain and troubleshoot | FasTest provides technical support for the life of the solution |
FasTest designs and manufactures custom connector designs, custom leak test fixtures, custom leak test systems, and modified standard products. Solutions range from a single purpose-built connector for a unique port to fully integrated multi-station test systems with automation and data acquisition.
A custom leak test fixture is an engineered assembly that positions and seals one or more connectors to a part being tested. Unlike individual connectors, a fixture addresses the complete test station interface—mounting, positioning, multi-port sealing, ergonomics, and integration with test equipment. FasTest custom leak test fixtures are designed for production-grade durability and maintainability.
A custom leak test system is a complete, integrated package that includes everything needed for a specific test application: custom connectors, fixtures, hose assemblies, manifolds, instrumentation, ICON™/SURE SEAL™ technology, and full documentation. Custom leak test systems are delivered production-ready and validated as a complete assembly.
Custom connector design starts with your port specification—geometry, material, thread form, sealing surface, pressure, media, and clearance constraints. FasTest engineers design a purpose-built connector with optimized seal geometry, materials, and actuation mechanism. The process includes CAD modeling, prototype production, validation testing, and production manufacturing.
FasTest has completed custom projects across automotive and EV manufacturing, aerospace, HVAC-R, compressed gas, medical and life science, fluid power, and appliance industries. If your application involves sealing a port or connection for testing, filling, or fluid transfer, our custom engineering team can help.
Timelines vary by complexity. A modified standard connector might take 2–4 weeks. A fully custom connector design typically takes 4–8 weeks from evaluation through delivery. Complex custom leak test fixtures and systems with prototyping and validation may take 8–12 weeks. Contact our team for an estimate based on your specific application.
Submit an Application Evaluation through our website, email your drawings and requirements to fastsales@fastestinc.com, or contact your local FasTest distributor. Include port drawings, CAD models, test pressures, media, cycle time targets, and photos of any current tooling problems. A FasTest custom engineer will review your application and follow up with a concept and timeline.
Yes. Many custom projects start with a standard FasTest connector that is then modified—changed seal materials, adjusted dimensions, added features, or adapted mounting interfaces. Modified standard products typically have shorter lead times and lower costs than ground-up custom designs.
Yes, when applicable. Custom leak test fixtures and custom connector designs built on the ICON™ platform include SURE SEAL™ seal confirmation, providing the same positive feedback and false-failure reduction as standard FasTest connectors.
Absolutely. Many of our custom leak test fixtures and systems are designed for semi-automated or fully automated production environments. This includes robotic connector positioning, PLC-integrated seal confirmation via SURE SEAL™, automated part handling compatibility, and multi-station fixture designs for parallel testing.
Yes. Every custom solution includes full documentation, maintenance parts availability, and ongoing technical support from FasTest. Your custom design is maintained on file for repeat orders, replacement parts, and future design updates as your product or process evolves.
The more detail you can provide, the faster the evaluation. Ideally, send port drawings or CAD models with dimensions, sealing surface specifications, test pressure and media, cycle time targets, clearance constraints or station layout drawings, photos of the current connection method (if any), and a description of the problems you’re trying to solve.