Services
Test Services
Testing both validates the design and confirms manufacturing processes
Developing a product testing, verification and validation strategy is an important part of the design process and readying a product for manufacturing. Testing confirms the design and identifies areas for improvement before weaknesses are revealed in the field. Executing a robust test plan will guide design toward increased reliability and designing a robust product.
At Zebulon Solutions, we incorporate validation testing into every design cycle. It closes the feedback loop between your product and your requirements. Whether we are developing test protocols, executing tests in-house or managing 3rd party labs, we will have a full suite of testing services to ensure your product meets its requirements.
It is just as important to have a product tested in manufacturing to ensure the quality of the product before shipment. Zebulon Solutions will design, build, and qualify your test stations to support production at your contract manufacturer.
Product Test
From design validation testing to life testing, we support every test need your hardware has. We will help you make sure your design aligns with all your requirements ranging from regulatory to performance and life testing.
Test Stations
Preventing defects from escaping to your customers protects your brand. Don't overlook developing your test stations before releasing your product to manufacturing.
The formula for success
Innovation. Experience. Integrity.
Ensuring your product meets the requirements during design, production and beyon.
Plan
We turn product requirements into detailed test plans and custom test systems to ensure your product performs as designed.
Design
Whether creating a test setup for engineering verification or a production test system, we ensure our test platforms meet your product's requirements.
Validation
We use the test plan to rigorously evalaute designs and ensure manufactured products fully meet specifications through custom test systems.
Product Test
Verification Testing
This is where the designers verify the product against the requirements. We anticipate the product will fail during this stage. These tests are intended to provide data that will guide design iterations.
Typically, these parts are prototypes and engineering modified components for testing.
- Engineering Verification Test (EVT)
- Test station mock-ups
- Performance requirements
- Corner cases
- Function at high and low temperatures
- Function at power droops
- Functions under all operating conditions
- Functions as defined in requirements
Validation Testing
- Design Validation Test (DVT)
- Drop testing
- Moisture ingress testing
- Temperature and humidity testing
- Customized test plans
Regulatory Pre-Testing
For products that must pass certification or regulatory testing, we replicate testing conditions to verify the product will pass before making the regulatory investment.
The parts we use for testing are from production processes and tooling.
- FCC/CE EMI pre-scans
- Equipment stability
- Acoustical sound measurement
- Temperature cycling and thermal testing
- Water and particulate ingress
- Mechanical hazards
- Patient and operator isolation and shock protection
- Electrical performance and leakage currents
This is not an exhaustive list, but representational of some of the testing we support and perform.
Life Testing
When a product needs to survive under adverse conditions or for an extended time, it is important to verify the product will perform as expected. We translate how many cycles of a specific condition is required by calculation of that condition over the life of the product.
The parts used for testing are from stabilized produciton processes and tooling.
- Accelerated testing
- Temperature cycling
- Heat and humidity testing
- Custom test stands for wear out
Production Test Stations
Test Strategy
There are many aspects of the product that need to be considered when developing a strategy. Some of the inputs we use to guide the process are listed below:
- Utilizing verification testing to identify what needs to be done on an on-going basis vs. validation testing
- Failure modes and yields from validation testing for manufacturing test
- The design of the product for testability
- Access to test points
- Functionality of the sub-systems and sub-assemblies
- Detection capabilities of sampling plans
- Cost of 100% testing
- What compromises are appropriate for the class of product (example: consumer vs. medical device)
Test Plan
Once a strategy is developed, we create a specific test manufacturing test plan to evaluate the cost and schedule for developing a manufacturing tester. Some of the items we consider in creating a comprehensive test plan:
- The parameters and functionality that needs to be tested
- The accuracy, precision, and repeatability needed
- Test time is estimated for product cost and shift capacity
- Use of off-the-shelf equipment vs. full customization
- Use of fixtures and operator interface
- Data collection and defect sequestration
- Estimate development time and costs
Tester Design & Development
Designing a test station is as complex as developing a product. It requires its own development schedule, budget, and must happen in parallel with designing the product it will test.
- Tester requirements documentation
- Test protocol development
- Burn-in duration calculation
- Fixture design
- Software creation
- Component purchasing
- Tester assembly
- Functional verification
Depending on the product’s volume, an investment in automation is evaluated.
Tester Qualification
Ensuring your testing provides accurate and repeatable results is critical to your business. Too many failures and yields are costly. While not capturing defects before shipment exposes your brand to risk. Partnering with a company who knows how to qualify your test station is paramount to your success.
- Gage R&R
- Golden part
- Calibration
Our Works
Partnering with a company that knows how to test the product and develop the test station can reduce your development time and costs.
Life Testing
Life testing to ensure the fleet will survive through generational change. Each failure is a statistical calculation on the age of the fleet.
Burn-in
A burn-in test station to ensure charge and discharge cycles are as expected. The lights on the wall above were indicators of power output from the batteries during the discharge cycle.
Verification Testing
Woven into our design progress is testing to ensure the design meets all of the necessary requirements prior to release to production. We create our own test fixtures or leverage existing tools to evaluate product.
Parametric Testing
Test stations to measure function parameters to ensure manufacturing defects are detected. A clear "pass" and "fail" output to facilitate the operator segregating bad product from good.
FAQ
What is EVT?
EVT is an acronym for Engineering Verification Test. It is used during the earlier phases and revisions of hardware product development. Typically, a small sample of parts are tested against the requirements to verify the product is designed as expected. It is common to repeat EVT several times to address failures.
What is DVT?
DVT is an acronym for Design Validation Test. It is used during the later phases and revisions of hardware product development. Typically, a statistical sample of parts are tested to validate the product meets all the requirements. Certification test conditions may be replicated to ensure certification testing will pass. Ideally, DVT is only completed once prior to releasing the design to manufacturing.
What is a production test station?
A production test station is custom-built equipment and software used on the factory floor to verify that every unit coming off the manufacturing line meets functional and quality requirements.
Why do contract manufacturers request production test stations?
A production test station us a tool that allows manufacturers to catch defects before they ship. They are able to monitor yield and make improvements to increase manufacturing yield.
How do you test hardware products before mass manufacturing?
Testing happens throughout development — from functional checks on early prototypes through formal reliability and regulartory testing before production — rather than only at the very end. This catches design issues while they’re still economical to fix.
What is in-circuit test (ICT)?
ICT is an automated test station to verify the electrical performance of circuit board populated with electrical components (PCBA). It is most effective when test points are added to the circuit during design and known input/outputs can be verified. It requires a custom fixture to hold the PCBA and pins to contact the test points on the PCBA.
What is functional testing for electronics?
Electrical functional test evaluates how the electrical circuits work before the PCBA is installed into the system. Unlike open and shorts test which looks for open or shorted circuits, functional test looks at analog and/or digital inputs/ outputs. It is based upon the PCBA schematic and customized for each PCBA.
How do you build a test fixture for a new product?
A text fixture is usually comprised of a mechanical support or mount that either plugs into sockets or contacts on the PCBA or has cables a production operator would attach. The fixture is connected to test equipment depending upon the function of the PCBA, but it may include network analyzer, power supply, or function generator. It is important to make sure the components of the test fixture are durable to support the anticipated production volume.
What certifications does a hardware product need before it can be sold (FCC, UL, CE, etc.)?
This depends on the industry, sales location, and customer expectation. Products sold into regulatory industries such as medical or automotive require more certifications than consumer products. Products sold in Europe require different requirements than Canada or those sold in the USA. Some examples:
- Electrical products need UL, CE, and/or CSA certificates
- Medical products need to be compliant with FDA regulations, such as ISO 13485
- Aeropsace products need to be compliant with FAA regulations, such as AS9100
- Consumer products are governed by safety and child protection regulations
Zebulon Solutions recommends working with a certification consultant to advise what certifications are required for your product. Reach out today for referrals to consultants we work with.
How do you catch reliability problems before a product ships?
Reliability is dependent upon the design of the product and the manufacturing process. During the development phase, it is helpful to initiate life testing to estimate the life of the product under accelerated conditions. In manufacturing, quality checks throughout the process can catch defects. Beyond that, adhering to manufacturing protocols such as ESD protection, cleanliness, and soldering standards such as IPC-610.