Pressure Testing

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Pressure Proof Testing for the Aerospace and Defense Industry

In the aerospace and defense industries, the reliability of pressure vessels, systems, and assemblies is critical to mission success and personnel safety. Thaler Defense Systems provides pressure proof testing services to validate the structural integrity and performance of components used in the most demanding environments.

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What Is Pressure Proof Testing?

Pressure proof testing verifies that a vessel, cylinder, or pressurized assembly can safely withstand specified internal pressures without leakage, deformation, or failure. The component is filled with a noncompressible fluid, typically water or hydraulic oil, and pressurized to a predetermined level—often above its normal operating pressure to confirm its structural and sealing integrity. During testing, we assess:

  • Structural integrity: Ensuring components retain their designed shape without swelling, bulging, or distortion.
  • Pressure retention: Verifying the ability to maintain pressure over a defined hold time without loss.
  • Leak detection: Identifying any leaks or seepage that could indicate system weakness.
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Partner with Thaler Defense Systems for Superior Defense Solutions

Coordination to gather any necessary technical data or documentation

Optional in-person or virtual meeting to review project requirements

A detailed, timely quote prepared by our business development and engineering teams

Complete confidentiality—your information is secure and never shared

Pressure Proof Testing Applications and Burst Testing for Aerospace and Defense

Thaler Defense Systems conducts pressure proof testing across a wide range of components and assemblies, including but not limited to:

  • Solid rocket motor cases
  • Combustion cases
  • Gas generators and cylinders
  • Specialized pressure-containing assemblies and components for aerospace platforms

All testing is performed using calibrated equipment, with full documentation provided to support customer and regulatory requirements.

Custom Testing Procedures and Standards Compliance

In addition to established testing methods, Thaler Defense Systems offers the development of custom pressure proof testing procedures tailored to unique customer specifications or application requirements. We work closely with our customers’ engineering and quality teams to:

  • Develop part specific test plans and criteria
  • Design and fabricate custom test fixtures as needed
  • Validate test results with detailed data capture and reporting
  • Meet or exceed applicable MIL-SPEC, ASME, and customer-defined standards

Our integrated approach ensures that testing is not simply a formality—it is a proven safeguard for mission-critical system reliability.

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