WAFU Brothers Leading the New Era of AI Intelligent Testing: Efficient and Precise Airtightness Detection Solutions

In the wave of smart transformation in manufacturing, airtightness testing—a key link in product quality assurance—is undergoing a profound shift from manual experience-driven methods to AI-powered intelligent systems. Leveraging 15 years of deep industry expertise, WAFU Brothers Technology has pioneered an intelligent airtightness testing solution that integrates AI algorithms, IoT, and big data analytics. This system provides "zero false detections, full traceability, and adaptive testing" for high-end manufacturing sectors such as automotive parts, new energy batteries, and medical devices, helping enterprises improve both quality and efficiency.

1. AI-Driven: Breaking Through Traditional Testing Bottlenecks

Traditional airtightness testing relies on fixed thresholds and manual experience, often facing high false detection rates and frequent missed detections under complex conditions. According to industry data, traditional methods have an average false detection rate of 8.7%, costing an automotive parts company over 4.2 million RMB annually in unnecessary rework. WAFU Brothers has reconstructed the testing logic with AI algorithms to solve these issues.

1.1 Dynamic Threshold Adaptive System

This system, based on CNN convolutional neural networks, automatically identifies leakage pattern features for different products. For example, in new energy battery pack testing, the detection precision improved from 0.01mL/min to 0.001mL/min, reducing false detection rates to below 0.3%.

A new energy battery manufacturer previously had a rework rate of 5.3% using traditional methods, costing about 350,000 RMB monthly. After adopting WAFU Brothers’ dynamic threshold system, the false detection rate dropped to 0.28%, saving 320,000 RMB per month, equivalent to 3.84 million RMB annually.

1.2 Multi-Sensor Data Fusion

By analyzing 12 dimensions of data including pressure, flow, temperature, and humidity, the system builds a 3D leakage model. This successfully solved the micro-leakage detection challenge for a medical device company, reducing the missed detection rate from 3.2% to zero.

For this medical device manufacturer, micro-leaks in infusion devices pose life-threatening risks to patients. Previous single-sensor methods often resulted in missed detections. After applying WAFU Brothers’ multi-sensor data fusion technology, these issues were eliminated, ensuring product quality and earning greater customer trust.

1.3 Real-Time Self-Learning Mechanism

The system automatically optimizes algorithms every 1,000 tests. A smartwatch manufacturer using this mechanism increased testing efficiency by 40% in 3 months, reducing the test cycle from 45 seconds to 27 seconds.

Previously, this manufacturer struggled to meet mass production demands due to low testing efficiency. With WAFU Brothers' real-time self-learning, detection speed increased progressively, effectively improving production efficiency and meeting market supply needs.

2. Full-Process Digitalization: Building a Transparent and Controllable Quality System

To address issues like “difficult to trace rework causes and unclear responsibilities” in traditional workflows, WAFU Brothers has developed an end-to-end digital solution.

2.1 Intelligent Traceability System

Each product is assigned a unique QR code containing 32 pieces of information including production time, device parameters, and testing data. Scanning the code retrieves the complete test report. One wiring harness manufacturer reduced traceability time from 3 days to 20 minutes.

Additionally, the system links abnormal data to process parameters. A home appliance company discovered mold wear issues through this function, preventing 1,200 defective products from entering the market and reducing quality-related losses.

2.2 Intelligent Decision Support

The AI analyzes historical data to predict equipment failure probabilities. A battery factory identified sensor aging in advance, avoiding 500,000 RMB in downtime losses.

The system also establishes a binary classification model of "real leak/false leak". After application, a contract manufacturer improved judgment consistency from 60% to 98%, saving 860,000 RMB annually in dispute resolution costs.

2.3 Cloud Platform Collaboration

Data from multiple factories can be synchronized in real time. A group enterprise unified detection standards across 12 factories, ensuring product quality consistency.

Clients can also remotely monitor the testing process. A foreign brand reduced inspection lead time from 7 days to 2 days, improving cooperation efficiency.

3. Scenario-Based Solutions: Customized for Industry Needs

WAFU Brothers has developed modular solutions tailored to various industry pain points, meeting the personalized needs of different sectors.

Industry	Core Requirement	Solution Highlights	Typical Customer Case
Automotive Parts	High-Pressure Detection Stability	0.5MPa Continuous Pressure Detection, ±0.01% Accuracy Control	CATL: 15 million parts tested annually, 99.98% pass rate
Medical Devices	Sterile Environment Adaptation	Fully Sealed Test Chamber, UV-C Sterilization System	Mindray Medical: 99.99% pass rate, meeting strict medical standards
Consumer Electronics	High-Precision Micro-Leakage Detection	Detection limit 0.005mL/min, 15-second rapid testing	Foxconn: 300,000 devices tested daily with zero missed detections
Aerospace	Extreme Environment Simulation	-40℃ to 120℃ Temperature Cycling, Pressure Fluctuation <0.05%	COMAC: Passed airworthiness certification testing to ensure reliability in extreme conditions

4. Technological Innovation: Building Three Core Competencies

4.1 Hardware Layer: Self-Developed Smart Sensors

Using MEMS micro-electromechanical technology, response time is improved to 0.01 seconds; interference resistance reaches IP68 level with <0.1% false detection in dusty environments; service life extended to 100,000 hours. An automotive company saved 1.2 million RMB annually in equipment replacement costs.

4.2 Algorithm Layer: Industry-Specific AI Models

Trained 108 specialized models for different product types; introduced transfer learning, reducing deployment time for new clients to 7 days; data is automatically anonymized to protect enterprise security.

4.3 Application Layer: Open API Ecosystem

Seamless integration with MES and ERP systems; a new energy enterprise achieved full-chain coordination of "testing–production–logistics". Provides a secondary development platform for customizable feature expansion; remote maintenance allows engineers to diagnose equipment status in real time, reducing downtime.

5. Value Validation: Success Cases from Benchmark Clients

Through follow-up with 300+ benchmark clients, WAFU Brothers’ intelligent testing solution has created significant value.

• A globally renowned automotive brand: Saved 18 million RMB annually in rework costs; customer complaints reduced by 75%; significantly improved product quality and market reputation.
• A leading medical device manufacturer: Testing efficiency tripled; certification cycles cut by 50%, enabling new products to hit the market 6 months earlier and seize market opportunities.
• A listed consumer electronics company: Reduced false detection rate from 5.2% to 0.5%; order volume increased by 20%, successfully entering the high-end market and enhancing competitiveness.

Conclusion: Ushering in a New Era of Intelligent Testing

In the context of "Made in China 2025" and "Industry 4.0", WAFU Brothers is driving the upgrade of airtightness testing from "quality assurance" to "value creation" through AI intelligent detection technology. With continuous innovation and deep industry integration, WAFU Brothers is committed to becoming the global smart testing partner for high-end manufacturing enterprises, setting new standards for the industry and injecting fresh momentum into "Quality Manufacturing in China".

If you would like to learn more about intelligent testing solutions or request the "Industry Intelligent Testing Upgrade White Paper", please contact the WAFU Brothers technical expert team for a personalized diagnosis and implementation plan.