Airborne Ultrasound (ABUS): The Complete Guide to Non-Destructive Seal Inspection

Airborne ultrasound (ABUS) is a non-destructive, non-contact inspection method that transmits high-frequency sound through a package seal and reads how much of that signal arrives on the other side — a strong, consistent signal means a well-bonded seal, and a disrupted signal marks a defect. It is the basis of PTI's Seal-Scan and Seal-Sensor product lines, recognized under ASTM F3004 and referenced in ISO 11607, and it has been in industrial use across food and medical device packaging for decades.

What does airborne ultrasound actually measure?

Unlike a leak test, which asks whether gas can pass through a package, airborne ultrasound asks whether a seal's layers are properly bonded — a physical, structural question rather than a leak-path question.

Is it just a pass/fail inspection tool?

No. Because it produces a continuous, quantitative signal rather than a single pass/fail bit, it can also function as a process analytical technology (PAT) — monitoring the sealing process itself in real time, not only the finished seal.

How does it compare to vacuum decay and manual visual inspection?

Each method answers a different question: vacuum decay is the more sensitive choice for a leak path through the whole package, manual visual inspection is the least reliable of the three, and airborne ultrasound is the only non-destructive, 100%-capable option for seal-formation defects on porous or opaque materials.

Where is it used in medical device packaging?

Airborne ultrasound is deployed across pouches, trays, and Class III device packaging, and it underpins PTI's broader seal-quality QRM strategy for medical device manufacturers.

Is this a proven technology, or something new?

Airborne ultrasound's use in packaging predates its medical device applications by decades, with a documented history in retort pouch and food packaging integrity going back to the 1990s and 2000s, long before its formal recognition as ASTM F3004.

How to use this guide:

start with how the technology works, then use the comparison page to check whether it is the right fit for your specific package and material, then go directly to the medical device or process-control page that matches your use case.