Are your defence vehicles safe from chemical attacks?

Why digital leakage simulation is redefining crew protection in the defence sector

For ISTAR (Intelligence, Surveillance, Target Acquisition and Reconnaissance) and other protected mobility platforms, armour and active protection systems tend to dominate the conversation. Yet a quieter, less visible vulnerability is rapidly becoming a frontline design priority: enclosure integrity. In an era of CNBR (Chemical, Nuclear, Biological and Radiological) threats, the question isn’t simply whether a vehicle is “airtight,” but whether it is sealed against uncontrolled air ingress.

Airtight doesn’t mean airless
Modern armoured vehicles are not sealed like submarines. Crews still need breathable air, and that air must come from outside. The difference is that it must enter through a single, intentional pathway: the vehicle’s CBRN filtration and overpressure system. This unit draws in external air, filters out contaminants, and pushes clean air into the crew compartment. By maintaining positive pressure, the system ensures that if any micro‑gaps exist, air flows outward, not inward.

But this only works if the hull is tight enough for the overpressure system to do its job. Even a 1mm gap in the wrong place can break the pressure balance, overwhelm filtration, and expose the crew to chemical or biological agents. That’s why “airtightness” in defence engineering really means no unfiltered air entering the vehicle at any point.

The hidden vulnerability: structural leaks
Traditionally, leak detection has been a reactive, late‑stage process. Engineers build a physical prototype, fill it with smoke or tracer gas, and manually search for leaks. This “blower door” approach is slow, expensive, and often too late to influence the design. If a leak is discovered after welding, the options are limited: add sealant, add weight, or accept a compromise.

In a world where NBC threats are evolving, “close enough” is no longer acceptable.

From reactive testing to ‘secure by design’
HAH Software is bringing Elsyca LeakageMaster to the UK and Ireland defence sector to change this paradigm. Instead of waiting for a physical prototype, designers can now simulate leakage digitally during the CAD phase — long before steel is cut or plates are welded.

With advanced digital leakage simulation, defence teams can:

• Automate detection: Identify microscopic gaps, imperfect seals, and geometric inconsistencies in complex CAD files.
• Verify integrity: Ensure the hull supports stable overpressure and that all airflow passes through the filtration system.
• Build a digital thread: Create a repeatable, quantitative reference for future vehicle programmes, reducing reliance on manual checks and human interpretation.

Precision that protects lives
Elsyca’s simulations have shown remarkable correlation with physical test results. This isn’t just about reducing prototype costs or avoiding unnecessary sealant weight. It’s about confidence — the confidence that when a vehicle enters a high‑threat environment, the crew is protected by a hull that performs exactly as intended.

The goal is simple: eliminate vulnerabilities in the digital phase so they never reach the battlefield.

If you’re involved in the design or procurement of protected mobility platforms, we’d welcome a conversation. Digital leakage simulation is reshaping how defence teams think about integrity — and redefining what “airtight” truly means.