Condom Testing

Electronic Testing

Electronic testing is the only test performed on every single condom, and it’s what manufacturers refer to when they say "individually" or "electronically" tested.

To perform the test, a condom is pulled over a metal form called a mandrel and placed into an intense electrical field. The field is created in air or water depending on the equipment used by the manufacturer. Because rubber does not conduct electricity, no electricity should reach the metal mandrel through the condom. If electricity reaches the metal mandrel, it indicates the presence of a pinhole. Any condom failing this test is automatically discarded by the machinery.

Dimensional Testing

Dimensional testing is performed on a random sampling of condoms from the same production lot. The length, width and thickness of the condoms are precisely measured according to published standards. If the samples do not meet the acceptance criteria, the entire batch is discarded.

Air Burst Testing

Condoms must be able to contain a minimum amount of air pressure and volume without breaking. To perform this test, a random sampling of condoms from the same production lot are filled with air until they burst. The air pressure and volume inside the condom are measured at the time the condom bursts. If the results are lower than published standards, the entire batch is discarded.

Package Integrity Testing

Once inside its wrapper, a condom must remain sealed until opened by a consumer. This test checks to see if the seal is intact. To perform the test, a random sampling of condoms from the same production lot are subjected to a vacuum to ensure there are no air leaks in the wrapper seal. If the results do not meet the seal acceptance criteria, the entire batch is discarded.

Leak Testing

Condoms must be free of any weakness that may cause them to leak. To perform this test, a random sampling of condoms from the same production lot are filled with water. The condoms are then inspected for signs of leakage as they are manipulated and held in various positions. If the results show any evidence of leaks, the entire batch is discarded.

Tensile Testing

For this test, condoms are laid flat and a section is cut out of the center leaving a latex ring. The ring is then placed on a device that stretches it until it breaks. The equipment measures the force required to break the condom and the amount of stretch or elongation at breakage. This information is recorded and used by manufacturers for their internal quality control. Tensile properties (force at break) testing is only performed when a manufacturer makes a claim of “extra strength”.