Custom Durability Testing Systems
Durability testing; also known as life cycle testing or fatigue testing; subjects a product or component to repeated mechanical stress that mimics its intended use. The goal is to accelerate years of wear into weeks of controlled testing.
At Testrium, we design and manufacture custom durability testing systems that replicate the exact motions, forces, and conditions your product will experience in real-world use. Our testers cycle components through 50,000 to 500,000+ repetitions to identify weaknesses before your customers do.
Just like the one-stop service we provide for our vibration testing clients, we also have the in-house capability to design and build the specialist fixtures and multi-station test systems necessary to validate your product’s lifespan with precision and efficiency.
Durability Testing
A durability tester automates the testing process by cycling a specific motion (open/close, push/pull, rotate, flex) continuously while monitoring for failure points, material fatigue, or performance degradation.
For example, when testing a truck tailgate, our durability tester cycles the gate through its full open-close motion—simulating a driver opening and closing it multiple times daily over 10+ years of ownership—compressed into a controlled test period. Our multi-station configurations allow testing of 2 or more samples simultaneously, maximizing throughput without compromising test integrity.
Unlike off-the-shelf testing equipment, Testrium systems are engineered specifically for your product and your testing requirements. We study your product’s real-world use case—how it moves, how often, under what loads, and in what environments—and this informs every design decision.
Whether you’re validating automotive tailgates, consumer electronics hinges, industrial latches, or medical device mechanisms, we build the test station that proves your product’s endurance.
Testing Capabilities
Testrium durability testers can be configured for a wide range of motion types and cycle counts depending on your product requirements.
Motion Types
- Open/Close Cycling: Doors, lids, tailgates, covers, hatches, access panels
- Push/Pull Cycling: Latches, buttons, drawer slides, levers, control mechanisms
- Rotational Cycling: Hinges, knobs, dials, rotating mechanisms, torque applications
- Flex/Bend Cycling: Cables, flexible connectors, material samples, wire harnesses
- Combined Motion: Complex assemblies requiring multi-axis movement patterns
Specifications:
- Cycle Range: 50,000 – 500,000+ cycles
- Station Configuration: Single or multi-station (2, 4, 6+ samples)
- Actuation Systems: Electro-mechanical, pneumatic, or hydraulic
- Environment Integration: Compatible with thermal chambers for combined environmental + mechanical stress testing
- Instrumentation Options: Load cells, displacement sensors, strain gauges, environmental monitoring
Our Process
Testrium’s custom design and build process ensures your durability tester is engineered specifically for your product and testing requirements.
Step 1: Define Requirements
We consult with your engineering team to understand the product, motion profile, target cycle count, and any environmental factors.
Step 2: Design & Engineering
Our engineers develop the fixture, actuation system, and control architecture. You review and approve before fabrication.
Step 3: Build & Validate
We fabricate the system, integrate all components, and run validation cycles to confirm performance meets specifications.
Step 4: Test Execution or Delivery
Depending on your preference, we execute the full test program and deliver results—or deliver the completed system to your facility with training and documentation.
Industry Served
Testrium durability testing systems serve a wide range of industries requiring life cycle validation.
Automotive
Tailgates, doors, hoods, trunk lids, seat mechanisms, console components, switch assemblies, mirror adjusters.
Consumer Products
Appliance doors, electronic device hinges (laptops, phones), furniture hardware, packaging closures, kitchen equipment.
Industrial & Heavy Equipment
Access panels, operator controls, safety latches, enclosure doors, equipment covers.
Medical Devices
Reusable device mechanisms, hinged housings, control interfaces, diagnostic equipment components.
Electronics & Technology
Laptop hinges, phone folding mechanisms, connector insertion cycles, button actuations.
Frequently Asked Questions
How long does a durability test take?
It depends on cycle speed and total count. A 100,000-cycle test running at 10 cycles per minute completes in approximately 7 days of continuous operation. We optimize cycle speed based on what your product can realistically experience.
Can you test in extreme temperatures?
Yes. We can design fixtures compatible with thermal chambers, or integrate heating/cooling elements directly into the test station for combined environmental and mechanical stress testing.
What data do you provide?
Standard deliverables include pass/fail determination and cycle-to-failure data. Enhanced instrumentation packages provide continuous force, displacement, and environmental data throughout the test duration with full reporting.
Do you offer testing services or just equipment?
Both. We can execute your durability testing program in our facility, or design and build a turnkey system for your internal use with complete documentation and operator training.
What's the typical lead time for a custom durability tester?
Lead times vary based on complexity, but most custom systems are designed, built, and validated within 6-12 weeks. Rush timelines may be available depending on current capacity.
More From Testrium
Vibration Testing Services
Vibration testing can be applied using either sine, random, sine-on-random or narrow band random-on-random control techniques.
Mechanical Shock Testing
The electrodynamic vibration test machines are also used to generate highly repeatable mechanical shock testing events.
BSR Testing
Buzz, squeak and rattle testing resolves annoying noises in vehicle interiors caused by incompatible contacting material pairs.
Custom Test Fixtures
We design and build specialist fixtures to interface between your product and test equipment for accurate, repeatable results.