In 2026, AMD Machines quoted a semi-automatic mass flow leak test station for a large hollow part at $125,000–$155,000 including freight and insurance to the buyer's plant, installation, commissioning and training, taxes excluded. One operator loads the part into a contoured nest, the station clamps and seals its openings, and a Cincinnati Test Systems (CTS) Sentinel IX5 instrument measures how much air it takes to hold test pressure.
The same station concept fits other large sealed parts where internal volume makes a pressure decay test a poor choice: molded tanks and reservoirs, appliance and HVAC housings and drain pans, battery enclosure trays and covers, pump, filter and valve housings, and large cast or fabricated housings. Prices are ranges from AMD Machines' 2026 quote. For the full range of leak and functional testing we engineer, see our automated test systems page. For production configurations of the same concept, see AMD Machines' automated leak test stations.
A mass flow leak test station is a machine that seals a part's openings, pressurizes it with air and measures the flow of make-up air needed to hold test pressure over time, so any measured flow above the limit marks the part as a leaker with an automatic pass/fail result. The AMD Machines station in this case study does that for one large part model, with an option for a second.
| Item | AMD Machines mass flow leak test station |
|---|---|
| Part family | Large hollow assemblies with openings sealed for the test; one model, two with the quick-change option |
| Station size | About 5 ft x 2.6 ft (1.5 m x 0.8 m), estimated maximum, sized to the large part it tests |
| Test method | Mass flow, with a CTS Sentinel IX5 leak and flow test instrument; automatic pass/fail |
| Loading | Manual, one operator; contoured nest with three laser seating sensors |
| Rate | 180 seconds per part including load and unload; about 150 seconds of that is the test |
| Price | $125,000–$155,000 with freight, installation and commissioning, taxes excluded |
| Lead time | 18 weeks from purchase order to factory acceptance test |
What Is in This Mass Flow Leak Test Station?
AMD Machines designs the station around an aluminum base machined to the part's contour. The operator loads by hand, three pneumatic clamps hold the part near its sealing areas, air-actuated seals close the openings, and the leak and flow instrument runs the test. AMD Machines specifies the equipment by brand in the quote:
| System | In the AMD Machines station |
|---|---|
| Test instrument | Cincinnati Test Systems (CTS) Sentinel IX5 leak and flow test instrument |
| Nest | Aluminum base machined to the part's contour |
| Seating check | Three laser part-present sensors that confirm the part is fully seated |
| Clamping | Three Destaco pneumatic clamps at the clamping contact areas, close to the sealing sections |
| Sealing | CTS air-actuated seals on SMC pneumatic actuators |
| Safety | Safety light curtains, Keyence or SICK |
| Operator signals | Status light: orange while loading, green when correctly nested; after the test, red for a leak and green for a pass |
| Option | Two fixture sets with dedicated sensors, Harting quick-change connectors and RFID tooling recognition that loads the test parameters automatically |
How Much Does a Mass Flow Leak Tester Cost?
AMD Machines quoted the station at $125,000–$155,000 with freight, installation and commissioning at the buyer's plant, taxes excluded. The quote prices it in two lines:
| Line in the AMD Machines quote | Price range |
|---|---|
| Machine: single-model base station (equipment in the table above) | $115,000–$145,000 |
| Freight and insurance to the buyer's plant, installation, commissioning and training | $9,000–$12,000 |
| Total, with freight, installation and commissioning | $125,000–$155,000 |
The quick-change second fixture is priced as a separate option in the AMD Machines quote, on top of that total.
How Does This Tester Compare With AMD's Published Ranges?
That total sits in the lower half of the range AMD Machines publishes for this kind of machine. AMD Machines' guide to what automation costs lists a "Leak / end-of-line test station" at "$75K – $250K". Its visual sibling, the bubble leak test station case study, comes in at "a two-rig bubble leak tester, $110K–$130K installed." That AMD Machines station is a visual bubble test in two rigs; this one is an instrument-based mass flow test in one fixture, with a red or green result after every test.
What Are the Payment Terms for a Mass Flow Leak Tester?
AMD Machines' payment terms for this station are 45% with the purchase order, 35% at design approval, 10% at approval at AMD's facility and 10% at approval at the buyer's facility. AMD Machines' standard terms carry a 12-month warranty.
What Moves the Price of a Mass Flow Leak Tester?
These choices move the price of a mass flow tester more than anything else:
- The instrument. Which leak and flow instrument the test needs changes the machine line.
- How many fixtures and models. One model needs one nest. The quick-change option adds a second fixture set, its sensors and RFID recognition.
- Seals and clamping per part. Every opening needs a seal, and every sealing area needs a clamp close by. More ports mean more of both.
- Loading. This station is operator-loaded. Robot or conveyor loading changes the machine and its price.
- Data. AMD Machines supplies the PLC tags; an ERP interface is extra scope.
Why Mass Flow Instead of Pressure Decay for a Large Part?
The part's large internal volume decides the method. AMD's engineering team does not recommend pressure decay for this application, because the part's volume makes it a poor fit for that method. The AMD Machines design uses mass flow instead: the instrument measures how much air the part needs to hold test pressure over time, and any flow indicates a leak.
AMD Machines selects a leak and flow instrument from a maker its engineers have worked with for years. After reviewing the application with the instrument maker's engineers, AMD's team expects a test of about 150 seconds. That is longer than the "15–30 seconds on large volumes" that AMD Machines' automated test systems page gives for a stable mass flow reading, and the reason is this part: its large internal volume sets the test time, and the final cycle is set in validation with real parts. For how the three main methods compare, see our comparison of leak testing methods.
AMD Machines also offers buyers validation before they order: send OK parts and parts with a known leak to AMD's office in Chicago, and AMD tests them to set the real cycle.
How Does the Station Keep a Large Part Sealed and Seated?
A leak tester can only be as good as its seal. Two features in the AMD Machines design protect the result:
- The operator cannot start a test on a badly seated part. The contoured nest locates the part, and three laser sensors must confirm it is fully seated before the status light turns green.
- The seals cannot lift during the test. AMD's engineering team places the three clamps close to the sealing sections, with clamp pressure points chosen so the air-actuated seals stay engaged for the full test.
Part tolerance matters too. Parts outside drawing tolerance may not fit the cavity or the seals and may not test correctly, so AMD Machines asks buyers to share any known part variation within 2 weeks after the purchase order.
How Does the Mass Flow Leak Test Cycle Run, Step by Step?
The AMD Machines station runs each part through four steps:
- The operator places the part in the contoured aluminum nest. The three laser sensors confirm it is fully seated, and the status light turns from orange to green.
- With the light curtain clear, the three pneumatic clamps close near the sealing areas.
- The air-actuated seals engage and the mass flow test runs: the CTS instrument measures the air needed to hold test pressure over time.
- The light shows red for a leak or green for a pass, the clamps release, and the operator unloads the part.
AMD Machines designs the station for 180 seconds per part including loading and unloading, with one operator per machine.
Can One Mass Flow Station Test Two Part Models?
Yes, with the quick-change option. AMD Machines keeps the same base frame and adds one fixture set per part, each with its own sensors. Harting quick-change connectors join the fixture to the machine, and RFID tooling recognition identifies the fixture and loads its test parameters automatically, so changeover needs no sensor calibration or manual setup.
Which Parts and Industries Does This Mass Flow Leak Test Station Fit?
AMD Machines' mass flow station concept fits manually loaded parts with a large sealed volume, in automotive, appliances, energy, heavy equipment and general manufacturing:
| Part family or application | Why it fits | What would change |
|---|---|---|
| Large molded plastic tanks and reservoirs | Large internal volume favors mass flow | Nest contour, seals and test pressure |
| HVAC and appliance housings, plenums and drain pans with sealed ports | The same operator-loaded nest-and-seal concept | More ports mean more seals and clamps |
| Battery enclosure trays and covers | A large sealed volume | A larger nest, possibly a second fixture through the quick-change option; a tighter leak specification may call for a different test method |
| Pump, filter and valve housings with several openings | The same seal-and-flow test | A smaller part may shorten the cycle |
| Large cast or fabricated housings | The same instrument | A steel or aluminum part changes the clamping and the nest material |
For these industries, see AMD Machines' automotive manufacturing automation, appliance manufacturing automation and general manufacturing automation pages.
What Safety Does a Mass Flow Leak Tester Need?
The operator loads at the nest, next to pneumatic clamps that close on the part. AMD Machines guards the station with Keyence or SICK safety light curtains, and the light curtain must be clear before the clamps close. The AMD Machines quote includes an ISO 12100 risk assessment, with a first draft before the factory acceptance test.
In your request for quote, specify UL 508A control panels and NFPA 79 machine wiring.
What Does the Mass Flow Leak Tester Quote Include and Leave Out?
The AMD Machines quote includes the machine, freight and insurance to the buyer's plant, on-site commissioning and training, the PLC programs and tags, and a 14-item documentation package:
- 3D and 2D files in STEP or SolidWorks format
- operator manual, troubleshooting guide and technician manual
- the ISO 12100 risk assessment, equipment specifications and installation guide
- electrical and pneumatic diagrams and a calibration list
- a preventive maintenance plan, a spare parts list and the bill of materials
- operation instructions and process parameters
Validation at AMD's facility runs on a production lot of 300 parts, or as the buyer requires, under AMD Machines' standard terms.
The quote leaves out:
- taxes
- ERP integration (AMD Machines supplies the tags only)
- unloading the crates and the utility hookups at the plant
- on-site support after final approval, quoted separately
- part models beyond the one quoted, or two with the option
- liability for a leaking part accepted in production; AMD Machines recommends periodic validation
How Long Does It Take to Build a Mass Flow Leak Test Station?
AMD Machines' lead time for this station is 18 weeks from purchase order to the factory acceptance test at AMD's facility. Installation through site acceptance takes 2–3 weeks more once the machine is in place.
For comparison, AMD Machines' published lead times are "simple machines in as little as 6 weeks; complex systems in 24–26 weeks that would take a typical overseas supplier 40–42." A single-station, operator-loaded tester sits between the two. See our custom automation lead times for what sets the schedule.
What Should You Send to Get a Mass Flow Leak Tester Quoted?
AMD Machines quotes a leak tester from your part and your specification. Send:
- part drawings and CAD for every model, with the sealing points marked
- the test pressure and the acceptable leak rate
- OK parts and parts with a known leak, for validation before the order
- the number of part models
- your required rate
- your data and traceability needs
Mass Flow Leak Tester FAQ
How much does a mass flow leak tester cost?
A single-model mass flow leak test station costs $125,000–$155,000 in a 2026 AMD Machines quote, with freight, installation and commissioning, taxes excluded. The machine is $115,000–$145,000, and freight and insurance, installation, commissioning and training add $9,000–$12,000. A second quick-change fixture is priced on top.
How long does a mass flow leak test take on a large part?
The part's internal volume drives it. For this large part, AMD Machines' engineers expect about 150 seconds of test inside a 180-second cycle that includes loading and unloading, with the final time set in validation on real parts.
Why not use pressure decay on a large part?
A large internal volume makes pressure decay a poor fit. AMD Machines' engineering team does not recommend pressure decay for this application. Its station measures the air needed to hold test pressure instead, and the status light shows red for a leak or green for a pass.
Can I test my parts before I order a leak tester?
Yes. AMD Machines offers to test OK and known-leak sample parts at its Chicago office before the purchase order, so the cycle is set on parts like yours.
If you're budgeting a leak tester for tanks, housings, enclosures or other large sealed parts, send us your part and specification and AMD Machines will tell you which method fits and what it costs.