From the Outside, It Looks Like an Aquarium. But It’s Actually How We Prove Cables Are Built to Survive.
If you walk through XACT’s Calgary facility, you might spot a clear acrylic tank sitting on a stainless-aluminum frame. At first glance, it looks suspiciously like an aquarium — but there are no goldfish here. This is our vacuum submersion leak testing system, one of the most critical steps in verifying the reliability of our rugged cable assemblies and overmolded connectors.
It’s not there for show. It’s where our cables go to prove they can handle anything.
What Is Vacuum Submersion Leak Testing?
Vacuum submersion testing simulates extreme real-world environments — rain, submersion, pressure changes, and temperature variation — to verify that sealed cables and connectors remain completely watertight.
Here’s how it works:
- The cable assembly is submerged in a controlled water tank.
- A vacuum pump removes air from the chamber, reducing pressure inside.
- Any trapped air within the assembly escapes as visible bubbles — exposing even the smallest sealing defect.
- This test is typically performed in accordance with MIL-STD-810 (Method 512) and IEC 60529 (IP67/IP68) requirements.
It’s one of the most effective ways to confirm that cables stay sealed under pressure — literally.
Why It Matters for Rugged Cable Assemblies
Environmental sealing isn’t optional in high-reliability industries. It’s what keeps mission-critical systems operational under real-world stress.
At XACT, vacuum submersion leak testing ensures:
- IP68-level protection against water and dust ingress
- Verification of overmold integrity on connectors and junctions
- Quality assurance for cables used in defense, energy, and industrial applications
- Consistency across facilities, since both Calgary, Alberta and Houston, Texas maintain identical testing capability
If it survives this tank, it’s ready for the field — whether that means the North Sea, the Texas heat, or a military vehicle wiring bay.
Behind the Tank
Our submersion test rigs are purpose-built for precision and repeatability:
- Acrylic vacuum chamber with stainless-steel hardware
- Digital vacuum gauges for real-time pressure monitoring
- Custom fixtures to secure assemblies during testing
- Integrated vacuum pump capable of controlled pressure cycling
This system allows us to simulate real environmental stressors — proving every XACT cable assembly can withstand them.
More Than a Test. It’s a Mindset.
Vacuum submersion testing is just one example of XACT’s “Tested to Prove It” philosophy.
We don’t just build to spec — we test until we’re confident the assembly will perform long after installation.
That’s why the tank sits where everyone can see it. It’s a constant reminder: quality isn’t assumed — it’s verified.
No Goldfish. Just Airtight Engineering.
From design to testing, XACT’s rugged cable assemblies are built to withstand — and tested to prove it.
Want to see how our assemblies perform under pressure?
Contact our engineering team to discuss your project’s test requirements.
FAQ: Testing and Reliability at XACT EMS
What testing capabilities does XACT EMS offer beyond vacuum submersion leak testing?
XACT EMS offers a comprehensive range of electrical, mechanical, environmental, and shielding tests — both in-house and through trusted lab partners. These include continuity, insulation resistance, dielectric withstand (Hi-Pot), signal integrity, RF performance & VSWR, strain relief and pull testing, flex and bend testing, shock and vibration simulation, salt fog/corrosion resistance, temperature and humidity chamber testing, shielding effectiveness, overmold adhesion validation, hermetic seal testing, visual inspection, and custom test jig design. Each test validates critical performance factors such as electrical integrity, sealing, durability, and EMI protection.
What standards do XACT EMS cable assemblies typically meet?
XACT EMS validates its rugged cable assemblies to meet or exceed IP68, MIL-STD-810, and a wide range of industry-specific and customer-defined standards.
- Military & Defense: MIL-SPEC, QPL, RoHS
- Energy / Oil & Gas: ATEX, NEMA, NEK 606
- Marine & Offshore: ABS, DNV, Lloyd’s Register
- Industrial / Power: IEEE, ICEA, UL 44
- Telecom: Telcordia GR-Series, TIA
- Transportation: AREMA, NFPA, ASTM, LSZH specifications
How does XACT EMS confirm the sealing integrity of overmolded connectors?
Through our vacuum submersion leak testing and hermetic seal validation processes, XACT EMS identifies even the smallest air leaks or water ingress. Combined with overmold adhesion validation, this ensures each cable assembly maintains its watertight and mechanically bonded seal over long-term use.
How does XACT EMS verify environmental durability?
How does XACT EMS ensure EMI and RF performance in shielded assemblies?
XACT EMS performs shielding effectiveness testing and RF performance/VSWR testing to evaluate how well assemblies prevent signal interference and maintain stable transmission characteristics in demanding electromagnetic environments.
Can XACT EMS design custom test fixtures or validation setups?
Yes. XACT EMS regularly develops custom test jigs and fixtures to replicate specific customer use cases or connector geometries. This allows us to perform accurate, repeatable QA on specialized or unique assembly configurations.
