Service · Functional Testing

Verify it works.
Catch defects early.
Before customer sees them.

Functional testing services for assembled products. Mechanical motion verification, electrical continuity, performance measurement, burn-in testing. Custom test fixtures, automated test sequences, statistical defect tracking.

Functional Testing Quote Light assembly

Custom test fixtures Automated test sequences Burn-in capable Statistical analysis

01 · Test capabilities

Functional test types.

Different products need different functional verification. We design and operate test stations for various product types.

Motion testing

Smooth operation

Test mechanical assemblies for smooth motion. Detect binding, misalignment, excessive friction. Common for gears, bearings, sliding mechanisms.

Electrical continuity

Connection verification

Verify electrical continuity through connectors, switches, harnesses. Detect open or short circuits.

Insulation resistance

Hi-pot testing

High-potential testing for electrical insulation integrity. Common for motors, transformers, power supplies.

Pressure testing

Sealed system

For pressure-containing products: leak rate verification, pressure cycle endurance. See pressure testing services for details.

Performance measurement

vs spec

Measure specific performance against specification — torque output, RPM, current draw, dimensional accuracy under load.

Burn-in testing

Stress to fail

Operate product under stressed conditions (elevated temperature, voltage) to identify infant mortality. Common for electronics.

Vibration testing

Survival verification

Verify product survives shipping vibration. Standard transport vibration profiles.

Drop testing

Impact survival

Drop from specified height to verify impact survival. Consumer product common test.

Functional sequence

Multi-step verification

Custom test sequence verifying multiple product functions in correct order.

02 · Test workflow

Functional test process.

Test specification

Define what passing functional looks like

Test fixture design

Custom fixture for product mounting and connection

Test sequence development

Step-by-step automated test sequence

Calibration

Test equipment calibration verified

Test execution

Each unit tested per sequence

Pass/fail recording

Results recorded for each unit

Failure investigation

Failed units investigated for root cause

Statistical tracking

Track pass rates, identify process drift

Reporting

Test reports with statistics for customer

FAQ

Functional Testing questions.

Test fixture cost depends on complexity. Simple electrical continuity fixture: $500-2,000. Complex multi-axis motion test fixture: $3,000-15,000. Automated test sequence with software: additional $5,000-30,000. For production volumes, fixture cost amortized over many parts. We design and build custom fixtures or work from customer-supplied designs.

Burn-in: operate product under stressed conditions to identify early-life failures. Typical: 24-72 hours at elevated temperature (40-85°C), elevated voltage (110% nominal), continuous operation. Reveals "infant mortality" defects that would fail in field use within first months. Standard for high-reliability electronics, not always cost-effective for consumer products.

Yes. Pass rate tracked per lot, per shift, per operator. Trends analyzed for process drift. Failure modes catalogued — identifying systematic issues vs random defects. SPC (Statistical Process Control) charts for production trending. Reports to customer per agreed frequency.

Failed units quarantined for investigation. Root cause analysis: visual inspection, dimensional check, X-ray for hidden defects. If repair possible: rework and re-test. If not: scrap with documentation. Customer notified of failure rate trends. For systematic failures, process improvement implemented.

Functional testing valuable when: (1) Failure cost in field is high (medical devices, aerospace). (2) Customer expects defect-free deliveries. (3) Multi-component assemblies where individual component testing isn't sufficient. (4) Production volumes justify test setup investment. For low-volume prototypes: testing per first article. For production: per agreed sampling plan or 100% testing.

Either. We can perform testing per customer specification (customer designs test, we execute). Or we can develop test specification per customer functional requirements. For production launch, we typically work with customer to define appropriate test coverage, then execute consistently. Joint test development common for new products.