Strategic Test Development for Complex Molded Assemblies
Testing of molded parts and full assemblies is essential to verify product performance. This testing requires a substantial investment of both time and money, so it is important it is performed correctly. Developing and performing custom test methods that are suitable for a unique product design and application requires the collaboration of engineering teams experienced in these methods. The engineers at The Madison Group apply their material and testing expertise into every product testing program. In this manner, we establish the best approach to evaluate molded parts and assemblies to confirm their performance.
If molded parts are tested in their optimal condition, test results may give a false sense of confidence that the design will meet its requirements over the lifetime of the product and could lead to unexpected failures in the field. The Madison Group understands how to properly condition parts before testing so that they better reflect their state in the application over the product’s lifetime.
We have developed reliable ways that testing can be accelerated. Due to the nature of accelerated testing, it is more susceptible to convolution. It is important to deconvolute the performance of improperly molded parts or inappropriate testing conditions during product testing so as not to extend the product development timeline and delay the launch of the product to market due to premature failures.
The Madison Group can help you achieve success in your product launch by supporting your team before, during and after production.
Ensure a successful production by testing your product before, and during production batches. Keep adequate quality control with periodic testing for production consistency.
Examples of test methods and capabilities that The Madison Group can offer to support your product testing goals:
- Test plan design – The creation of an appropriate test plan to adequately verify product performance that correlates with requirements of your part.
- Test method development – The development of test methods that are reliable and repeatable to obtain accurate information regarding the performance of parts under application-like situations.
- Proof load testing – The mechanical evaluation of parts or assemblies under load to determine their performance.
- Performance assessment – The physical evaluation of parts or assemblies following a variety of environmental exposure conditions including, chemical, ultraviolet (UV) light, and heat aging, to name a few.
- Dimensional Analysis and X-ray Computed tomography (CT) scanning – Multiple test methods can be applied to evaluate part quality through a review of part dimensions, assembly fit, shrinkage and warpage, void and porosity, quality of welds, of seals and assembly joints.
Using our vast experience in processing, testing, mechanical behavior, and failure analysis of plastics, The Madison Group can develop a product test method that best addresses the concerns for your part in its application.
Physical Prototype Testing / Engineering Mechanics
A significant step in any product design validation process is the testing of physical prototypes. Important information can be gained about the influence of the material, part design, and manufacturing on the end product.
The Madison Group can assist customers in the design and custom testing of manufactured parts to help determine:
- Expected mode of failure
- Maximum load to break
- Strain to break
- Chemical compatibility
- Mechanical response to physical aging, UV, and thermal stressors
Quality Assessment
A critical aspect of any production part is how well it meets its established quality requirements. Typically, custom test methods may need to be developed to evaluate the quality of specific part geometries and assemblies. Our team of engineers is capable of helping you through the development and execution of recommended test methods to verify quality of manufacturing and production.
We have helped many clients develop product test methods that have led to identifying serious issues before these resulted in catastrophic failures:
- Testing for degradation of parts due to poor processing.
- Analysis of parts for voids and porosity affecting the structural integrity of high stress regions.
- Qualitative examination of birefringence patterns.
- Dimensional analysis confirming warped parts not manufactured to print leading to elevated assembly stresses and a potential for creep fracture.
- Analysis of seal quality for the identification of potential leak paths in an assembly.
Many times, it is necessary to develop non-destructive methods of evaluation for defects and imperfections. Over the years we have explored and applied many testing techniques to resolve unique problems through the use of non-destructive procedures. Many of these techniques are also commonly applied in failure analyses investigations where the preservation of evidence is crucial to an investigation.
Common non-destructive techniques may include spectroscopy for material verification in a product or Computed Tomography (CT) scanning. Contamination of a product can lead to unforeseen weaknesses that could result in premature failure. The presence of voids and out-of-tolerance dimensions can lead to stresses on a part that may affect the long-term performance of the part.
Examples of non-destructive product testing methods may include:
- CAD to part dimensional analysis
- Void and porosity detection
- Non-destructive evaluation of assemblies
- Non-destructive evaluation of component fit and function
- Non-destructive evaluation of weld joints
- Seal groove analysis for the identification of potential leak paths
CT Scanning can be an excellent tool for examining assemblies and for non-destructively evaluating a part for defects.
Example of a shallow CT Scan
Example of a deeper CT Scan
Testing a product in the development stages and during production is a crucial step in the development and successful manufacturing of any product. These steps will reduce the chances of facing problems down the road when the product is in use.
Frequently Asked Questions
Test Development & Strategy
Why should I use custom product testing instead of standard material tests?
Standard tests (like ISO or ASTM) evaluate generic material properties, but they don’t account for your part’s unique geometry, molding and assembly stresses, or manufacturing defects. Custom product testing simulates the specific environment and mechanical loads your part will face in the real world to ensure it performs as intended.
Can you help me create a testing plan from scratch?
Yes. One of our primary services is “Test Plan Design.” We analyze your part’s requirements and develop a reliable, repeatable testing protocol that correlates with your real-world performance goals, ensuring you aren’t wasting time or money on irrelevant tests.
What is “accelerated testing,” and how accurate is it?
Accelerated testing uses higher temperatures, increased loads, or more intense environmental exposure to simulate years of service life in a few weeks or months. We specialize in conditioning parts properly before testing so that these accelerated results accurately reflect the product’s natural state over its lifetime.
Testing Capabilities
Do you offer non-destructive testing (NDT)?
Yes. We use various non-destructive techniques, including X-ray Computed Tomography (CT) scanning and spectroscopy. These allow us to inspect internal voids, porosity, assembly fit, and weld quality without destroying the sample.
Can you test how my product reacts to specific chemicals or environments?
Absolutely. We conduct performance assessments following exposure to a wide range of stressors, including chemical agents, UV light, humidity, and heat aging. This is critical for predicting if a part will embrittle, crack, or lose structural integrity over time.
What is “Proof Load Testing”?
Proof load testing is the mechanical evaluation of a part or full assembly under a specific load to determine its performance limit. We use this to identify the expected mode of failure, the maximum load to break, and the strain limits of your specific design.
Quality & Production Support
Can you help me troubleshoot quality issues with production parts?
Yes. If your manufactured parts are failing or performing inconsistently, we can test for degradation caused by poor processing, voids/porosity in high-stress regions, or contamination that may be weakening the polymer structure.
How do you evaluate the quality of welds and seals?
Depending on the application and part geometry, we can develop custom fixtures for stress, pressure, or performance testing. We also use CT scanning and dimensional analysis to perform seal groove analysis (identifying potential leak paths) and to evaluate the structural integrity of weld joints. This ensures that the assembly process isn’t the “weak link” in your product.
Project Logistics
Do I need to provide physical prototypes or CAD files?
Both are helpful. CAD files allow us to perform dimensional analysis and prepare for testing, while physical prototypes are essential for the actual lab evaluations. We can test everything from early-stage prototypes to final production samples.
How do I ship my parts to your lab for testing?
After talking to one of our associates, you can ship parts directly to our headquarters in Madison, WI.
Inquire Today
The Madison Group is always available to assist with any of your product testing needs. Whether you are developing a new product or applying steps to improve the part-to-part quality of an existing one, we have the experience to help you develop cost effective solutions. Contact us today and request information that will help you become a product market leader.
