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Burst Testing – Everything You Need to Know

Burst testing is an essential process for identifying the weak link in a component or assembly. It provides valuable information about the design and can help improve a component’s efficiency. However, it can also cause over-engineering, which is detrimental to the component’s economy. 

Test Steps

Many people wonder and check on sites about “burst testing near me“ and its function. Burst testing is a crucial design step, as it pinpoints the weak links in an assembly or component. It can also provide valuable information about the design. The results of burst testing may help improve a design and minimize the risk of physical failure. In some cases, overengineering a component may result in poor performance. Still, it can also help a manufacturer save money by reducing the number of pieces needed to create the finished product. A variety of different methods can perform burst tests. In conventional tests, two primary variables are controlled: the rate of pressurization (the rate at which the internal pressure of a package increases) and the height of the lid restraint, or the height at which a lid can expand. 

Controllable Parameters

Burst pressure measurements can be a challenging process. Many factors can influence the actual pressure during a burst test, including the shape of the working area. The ideal geometry is a semicircular surface, which can be challenging to model with force diagram analysis. When performing a burst test, controlled parameters are important to determine the integrity of the package. The maximum burst pressure of the package is a critical design parameter that can help establish safety design margins. It can also assure manufacturers and customers that the package will hold up in a new application. Failure is not an option, so it is important to determine the maximum burst pressure for the package. Burst testing is essential because it identifies weak links in the component or assembly. The results can provide valuable information about how to improve the design. In some cases, more than improvements in design are needed to fix physical flaws. Other times, a component may be over-engineered, which can hurt the economics of the part. However, it can ultimately benefit the manufacturer by reducing the per-piece cost.

Regulatory Requirements

Burst testing is an essential part of the safety process for medical devices and packaging systems. The test allows for a comprehensive evaluation of the product’s performance under pressure. Because medical products are placed under pressure over their entire life, they need to be able to sustain a certain level of pressure.

Burst tests are conducted on 100% of the seams of a product. This includes seams that are tens of PPI. It is important to note that the test is conservative. It will give more failures than passes. In this case, the burst test is conservative and will often fail more seams than pass. Burst testing is often used to determine the weakest point of a package seal. This is useful for determining the material’s ultimate tensile strength and assisting in selecting the material. It can also determine the optimal wall thickness and component geometry.

Impact On Quality

Burst testing is a critical process for ensuring the quality of packaging materials. This ensures that the materials remain intact during transportation, guaranteeing the products’ safety. Burst testing can also be used in the textile and industrial sectors, where it is essential to ensure the highest strength and quality of the fabric or material. If the fabric or material fails during testing, it can cause costly consequences.

Burst testing can also identify weak points in a component or assembly. This information is helpful for improving the design, as it shows what components or assembly parts are prone to failure. However, not all physical flaws can be remedied through improvements in design.


Burst testing is vital for the safety of medical devices and packaging systems. It provides insight into the pressure level at which a product will fail. This test is performed on medical devices such as IV catheters, check valves, and pouches. These devices are exposed to pressure throughout their lifetime, and this test can help ensure that they can withstand the pressure. There are many different types of burst testing equipment available on the market. Different industries set various standards and regulations to ensure the safety of their products. This means that manufacturers must comply with industry regulations and international testing standards. Burst testing is an integral part of these standards.

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