Delserro Engineering Solutions - Product Reliability & Vibration Testing Since 1982

The Importance of ISTA Testing for Global Product Shipping

In today’s globalized world, products are shipped across continents, facing numerous challenges during transportation. From rough handling to extreme temperature fluctuations and vibration, packages must endure a multitude of hazards to ensure that the products inside reach their destinations in good condition. This is where the International Safe Transit Association (ISTA) package testing standards come in. These comprehensive and rigorous ISTA testing procedures have been developed to help manufacturers and distributors evaluate the performance and durability of their packaging and products during transportation, minimizing potential damage and ensuring a positive customer experience.

Benefits of Adhering to ISTA Packaging Standards

ISTA packaging standards encompass a wide range of procedures, each designed to assess various aspects of packaging performance under different conditions. These standards provide numerous benefits to businesses, consumers, and the environment. By adhering to ISTA testing standards for packages, manufacturers and distributors can:

Enhance customer satisfaction: When products arrive in good condition, customers are more likely to be satisfied with their purchase, increasing the likelihood of repeat business and positive reviews.
Reduce product damage and returns: Properly tested packaging helps to prevent product damage during transit, reducing the need for returns, replacements, and refunds. This, in turn, can lower operational costs and improve a company’s bottom line.
Minimize environmental impact: By ensuring that packaging materials can withstand transportation hazards, companies can reduce waste generated from damaged products and discarded packaging. They can also test various package designs to optimize the amount of materials required. This contributes to a more sustainable supply chain and a reduced carbon footprint.
Improve supply chain efficiency: ISTA testing standards for packages enable businesses to identify weaknesses in their packaging and make necessary improvements. This leads to a more efficient supply chain, with fewer delays and disruptions caused by damaged products.
Facilitate global trade: ISTA testing standards for packages are recognized and accepted worldwide, ensuring that products can be shipped safely and securely across international borders. This promotes global trade and helps companies to access new markets.
Streamline regulatory compliance: Adhering to ISTA testing standards for packages can help businesses meet national and international packaging regulations and requirements. This simplifies regulatory compliance and reduces the risk of penalties and fines.
Foster innovation: ISTA testing standards for packages encourage manufacturers to develop new and innovative packaging materials and designs that can better withstand transportation hazards. This promotes technological advancements and drives the packaging industry forward.

Different Types of ISTA Tests: A Comprehensive Overview

ISTA has organized its test procedures into several series, each with unique characteristics and purposes. These series of ISTA packaging testing standards include:

Series 1 Tests: ISTA 1 Series tests are package integrity performance tests not meant to simulate environmental occurrences. They are simple and inexpensive screening tests used to evaluate whether problems in shipment or product damage will occur. ISTA Series 1 tests are useful to compare the performance of various package designs. The ISTA Series 1 is divided into the following procedures:

ISTA 1A, Integrity Testing for Packaged-Products weighing 150 lb. (68 kg) or Less
ISTA 1B, Integrity Testing Packaged-Products weighing Over 150 lb. (68 kg)
ISTA 1C, Extended Integrity Testing for Individual Packaged-Products weighing 150 lb. (68 kg) or Less
ISTA 1D, Extended Integrity Testing for Individual Packaged-Products weighing Over 150 lb. (68 kg)
ISTA 1E, Integrity Testing for Unitized Loads
ISTA 1G, Packaged-Products weighing 150 lb. (68 kg) or Less utilizing Random Vibration
ISTA 1H, Integrity Testing for Packaged-Products weighing Over 150 lb. (68 kg) utilizing Random Vibration

Series 2 Tests: ISTA 2 Series are partial simulation performance tests. They are designed to evaluate the durability of product packaging and should be considered for international distribution. The ISTA Series 2 is divided into the following procedures:

ISTA 2A, Packaged-Products weighing 150 lb. (68 kg) or Less
ISTA 2B, Packaged-Products weighing over 150 lb. (68 kg)
ISTA 2C, Furniture Packages

Series 3 Tests: ISTA 3 Series are general simulation performance tests. They are designed to evaluate the capability of the package and product to withstand transport hazards. They simulate a variety of vehicle types, routes, and number of handling exposures. The ISTA Series 3 is divided into the following procedures:

ISTA 3A, Parcel Delivery System Shipments 150 lb. (70kg) or Less
ISTA 3B, Less-Than-Truckload (LTL) Shipment
ISTA 3E, Similar Packaged-Products in Unitized Loads for Truckload Shipment
ISTA 3F, Distribution Center to Retail Outlet Shipment 100 lb. (45 kg) or Less
ISTA 3H, Mechanically Handled Bulk Transport Containers
ISTA 3K, Fast Moving Consumer Goods for the European Retail Supply Chain
ISTA 3L, Generalized E-commerce Retailer Fulfillment

Series 4 Test: ISTA 4AB is the only protocol in this series. It is a web-based software that generates enhanced simulation test plans.

Series 5 is not an active series.

Series 6 Tests: ISTA 6 series are member performance tests created to meet the specific shipping requirements of certain Global 500 Retailers or Carriers. The ISTA Series 6 tests are divided into the following procedures:

6-FEDEX-A, FedEx Procedures for Testing Packaged Products Weighing Up to 150 lb.
6-FEDEX-B, FedEx Procedures for Testing Packaged Products Weighing Over 150 lb.
Project 6-AMAZON.COM-SIOC, Ships in Own Container (SIOC) for Amazon.com Distribution System Shipment
Project 6-AMAZON.COM-Over Boxing, e-Commerce Fulfillment for Parcel Delivery Shipment
Project 6-SAMSCLUB, Packaged-Products for Sam’s Club® Distribution System Shipment

Series 7 Tests: ISTA 7 series are development protocols. They can be used to compare the relative performance of various container designs but are not meant to evaluate the protection provided by packaged products.

ISTA 7D, Temperature Test for Transport Packaging
ISTA 7E, Testing Standard for Thermal Transport Packaging Used in Parcel Delivery System Shipment

Conclusion

ISTA testing standards for packages play a vital role in ensuring the safe and efficient transportation of goods around the world. By evaluating the performance and durability of packaging materials under various conditions, these standards help manufacturers and distributors to improve customer satisfaction, reduce product damage, minimize environmental impact, and streamline their supply chains. As global trade continues to expand, the importance of adhering to these standards will only grow, benefiting businesses, consumers, and the planet as a whole.

DES ISTA Testing Lab for Optimal Results

DES performs ISTA testing for the medical device, electronic, automotive, and aerospace industries within their environmentally controlled, accredited laboratory. We can help ensure that your package design will protect your product from damage during the transportation and distribution process. DES is unique because we can help you with BOTH package testing evaluations and product reliability testing thanks to our top-notch testing services.

Choose Delserro Engineering Solutions for Your ISTA Testing Needs

In summary, ISTA testing plays a crucial role in ensuring the safe and efficient transportation of products across the globe. By partnering with Delserro Engineering Solutions, you can be confident that your packaging will meet industry standards and protect your products during shipping. Our commitment to quality, accuracy, and fast turnaround times makes us an ideal choice for your ISTA testing needs. Contact us today to learn more about our services and how we can help you improve your packaging and product reliability.

DES has top-of-the-line package test equipment from leading manufacturers. We are committed to quality, accuracy, thoroughness, and a fast turnaround. Please contact a professional if you have any questions.

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ISTA Series 1 Package Testing Standards

ISTA 1 tests are Non-Simulation Integrity Performance Tests meant to evaluate the strength and robustness of the product and package combination. Each of the ISTA 1 test procedures (1A, 1B, 1C, 1D, 1E, 1G, and 1H) include a combination of tests to assess the ability of packaging to withstand different transportation hazards. These tests help manufacturers and distributors identify weaknesses in their packaging and product designs, and ultimately make improvements to ensure products arrive at their destinations in good condition. All ISTA 1 tests share the common goal of minimizing potential shipping issues and product damage during transportation.

What are the benefits of ISTA Series 1 Package Tests? They can:

Evaluate the durability of individually packaged products
Compare the performance of various package and product design alternatives
Test that your products will arrive unharmed at their destination
Provide a cost-effective screening test to evaluate potential shipping issues or product damage
Shorten package development time and gain confidence before launching products

The ISTA 1 tests are divided into the following procedures:

ISTA 1A, Integrity Testing for Packaged-Products weighing 150 lb. (68 kg) or Less
ISTA 1B, Integrity Testing Packaged-Products weighing Over 150 lb. (68 kg)
ISTA 1C, Extended Integrity Testing for Individual Packaged-Products weighing 150 lb. (68 kg) or Less
ISTA 1D, Extended Integrity Testing for Individual Packaged-Products weighing Over 150 lb. (68 kg)
ISTA 1E, Integrity Testing for Unitized Loads
ISTA 1G, Packaged-Products weighing 150 lb. (68 kg) or Less utilizing Random Vibration
ISTA 1H, Integrity Testing for Packaged-Products weighing Over 150 lb. (68 kg) utilizing Random Vibration

ISTA 1A to ISTA 1E: Packaging Up to 150 Pounds and above (1B, 1D, 1E)

ISTA 1A Package Testing

ISTA 1A is a package test procedure for individually packaged products weighing up to 150 pounds. The table below provides the test sequence required for ISTA 1A. ISTA 1A is the same as ISTA 1G except for the vibration. ISTA 1A uses fixed displacement vibration while ISTA 1G specifies random vibration.

Sequence	Test Category	Test Type	For ISTA Certification
1	Atmospheric Preconditioning	Laboratory ambient temperature and humidity	Required
2	Vibration	Fixed Displacement	Required
3	Shock (alternative methods allowed-select one test type)	Package Drop Test or Inclined Impact or Horizontal Impact	Required

ISTA 1B Package Testing

ISTA 1B is a protocol for individually packaged products weighing more than 150 pounds. ISTA 1B is the same as ISTA 1H except that ISTA 1B specifies fixed displacement vibration whereas 1H uses random vibration. The table below provides the test sequence required for ISTA 1B.

Sequence	Test Category	Test Type	For ISTA Certification
1	Atmospheric Preconditioning	Laboratory ambient temperature and humidity	Required
2	Vibration	Fixed Displacement	Required
3	Shock (alternative methods allowed-select one test type)	Package Drop Test (6 in) or Inclined Impact (69 in/sec) or Horizontal Impact (69 in/sec)	Required
4	Shock	Rotational Edge Drop (8 in)	Required when not testing face 1

ISTA 1C Package Testing

ISTA 1C is an extended package test procedure designed for individually packaged products weighing 150 pounds or less. ISTA 1C adds compression testing vs. 1A or 1G and gives alternative choices for vibration. The test sequence is listed below.

Sequence	Test Category	Test Type	For ISTA Certification
1	Atmospheric Preconditioning	Laboratory ambient temperature and humidity	Required
2	Compression Testing (alternative methods allowed-select one test type)	Compression Tester, apply and release Compression Tester, apply and hold Weight and Load Spreader	Required
3	Vibration (alternative methods allowed-select one test type)	Fixed Displacement or Random Vibration	Required
4	Shock (alternative methods allowed-select one test type)	Package Drop Test or Inclined Impact or Horizontal Impact	Required

ISTA 1D Package Testing

ISTA 1D is an extended test protocol for individually packaged products weighing more than 150 pounds. ISTA 1D is the same as 1B or 1H with the addition of compression testing and alternative choices for vibration. The test sequence is shown below.

Sequence	Test Category	Test Type	For ISTA Certification
1	Atmospheric Preconditioning	Laboratory ambient temperature and humidity	Required
2	Compression Testing (alternative methods allowed-select one test type)	Compression Tester, apply and release Compression Tester, apply and hold Weight and Load Spreader	Required
3	Vibration (alternative methods allowed-select one test type)	Fixed Displacement or Random Vibration	Required
4	Shock (alternative methods allowed-select one test type)	Package Drop Test (6 in) or Inclined Impact (69 in/sec) or Horizontal Impact (69 in/sec)	Required
5	Shock	Rotational Edge Drop (8 in)	Required when not testing face 1

ISTA 1E Package Testing

ISTA 1E is for testing unitized (palletized) loads made up of either single or multiple products or packages of the same products. The test sequence is shown below.

Sequence	Test Category	Test Type	For ISTA Certification
1	Atmospheric Preconditioning	Laboratory ambient temperature and humidity	Required
2	Vibration (alternative methods allowed-select one test type)	Fixed Displacement or Random Vibration	Required
3	Shock (alternative methods allowed-select one test type)	Inclined Impact (69 in/sec) or Horizontal Impact (69 in/sec)	Required
4	Shock	Rotational Edge Drop (8 in)	Required

Vibration and Shock Testing for Packages Up to 150 lb (ISTA 1G) & above (ISTA 1H)

ISTA 1G Package Testing

ISTA 1G is a package test procedure applicable to individually packaged products weighing 150 pounds or less. Like ISTA 1A, it evaluates the strength and robustness of the product and package combination without simulating actual environmental conditions. The primary difference between ISTA 1A and ISTA 1G is the vibration testing, with ISTA 1A using fixed displacement vibration and ISTA 1G specifying random vibration.

Sequence	Test Category	Test Type	For ISTA Certification
1	Atmospheric Preconditioning	Laboratory ambient temperature and humidity	Required
2	Vibration	Random Vibration	Required
3	Shock (alternative methods allowed-select one test type)	Package Drop Test or Inclined Impact or Horizontal Impact	Required

ISTA 1H Package Testing

ISTA 1H is a protocol for individually packaged products weighing more than 150 pounds. ISTA 1H is the same as ISTA 1B with the exception that ISTA 1H specifies random vibration. The test sequence is listed below.

Sequence	Test Category	Test Type	For ISTA Certification
1	Atmospheric Preconditioning	Laboratory ambient temperature and humidity	Required
2	Vibration	Random Vibration	Required
3	Shock (alternative methods allowed-select one test type)	Package Drop Test (6 in) or Inclined Impact (69 in/sec) or Horizontal Impact (69 in/sec)	Required
4	Shock	Rotational Edge Drop (8 in)	Required when not testing face 1

ISTA 1 Series: Comprehensive Testing for Optimal Product Shipping and Delivery

ISTA package testing standards play a pivotal role in ensuring that products arrive in optimal condition at their destinations. These tests help manufacturers and distributors evaluate the durability and performance of their packaging and compare different packaging and product design alternatives. To ensure their products meet these standards, companies can rely on professional package testing services from accredited laboratories, delivering a safe and satisfying experience.

DES provides package testing services to the medical device, electronic, automotive, and aerospace industries within their environmentally controlled, accredited laboratory. Please contact an expert if you have any questions.

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Package Test Equipment for Diverse Industries

Delserro Engineering Solutions (DES) is excited to announce the addition of advanced, state-of-the-art package test equipment focused on enhanced testing to our already extensive range of testing capabilities. Our commitment to staying at the forefront of technological advancements enables us to provide our clients with comprehensive and cutting-edge testing solutions that cater to the diverse requirements of various industries.

lansmont-squeezer-test-equipment — Lansmont Squeezer Compression Test System

Our continuous investment in new package test equipment allows us to expand our capacity and meet the growing needs of our clients in sectors such as aerospace, automotive, consumer goods, electronics, medical devices, and more. By combining our decades of expertise in testing services with the latest equipment, we ensure that our clients receive accurate, reliable, and efficient solutions for all their packaging needs.

The Vibration Tester: Ensuring Package Performance

One essential component of our testing arsenal is the vibration tester, which enables us to assess a package’s performance under various vibration conditions. With the help of our advanced vibration tester, we can identify potential weaknesses in the packaging and ensure that products remain protected during transportation and handling.

DES understands that each industry and client has unique packaging challenges, and our expanded testing capabilities allow us to customize our services to meet these specific requirements. Whether your focus is on improving durability, ensuring product safety during transportation, or meeting strict regulatory standards, our state-of-the-art package test equipment and experienced team of engineers are here to help you achieve your goals.

ASTM D4169 and Other Industry Standards for Package Testing

DES is committed to meeting and exceeding industry standards for package testing. The new package equipment, including the Lansmont Squeezer Compression Test System, is designed to perform compression testing in accordance with ASTM D642, ASTM D4169, and TAPPI T804. By adhering to these established guidelines, DES is committed to providing testing services that meet the highest levels of quality and reliability. For more information on these standards, see our frequently asked questions (FAQ) section below.

In addition to enhancing our existing services, the new package test equipment also allows us to explore innovative testing methods and stay ahead of emerging trends in the packaging industry. Our commitment to continuous improvement ensures that we not only meet the current demands of our clients but also anticipate and address future challenges.

Ready to ensure your packaging meets industry standards? Request a quote today and speak with our experts to discuss your package testing project.

Expanding our Package Test Equipment Portfolio

DES has recently added two cutting-edge pieces of package test equipment to our lineup: the Lansmont PDT 80 package drop tester and the Lansmont Squeezer.

The Lansmont PDT 80 Precision Drop Tester can test packages weighing up to 177 lbs., with a drop height range of 12 to 72 inches. Capable of performing flat, edge, and corner drops, the package drop tester meets the requirements of ASTM D5276 and ISO 2248.

The Lansmont Squeezer Compression Test System is specifically designed to perform compression testing on packages, including constant load tests that simulate long-term warehouse stacking. Featuring a platen size of 30 x 30 inches and a maximum opening of 48 inches, the Squeezer boasts a force capability of up to 5,000 lbs.

In addition to the new Lansmont package test equipment, DES has an altitude chamber and multiple temperature/humidity chambers to simulate various environmental conditions during testing.

DES offers ASTM and ISTA Package Testing services within our environmentally controlled, accredited laboratory. For more information on our package testing capabilities or to discuss your package testing project with one of our experts, please contact us or call 610.253.6637. Our team is committed to providing exceptional testing services to ensure the utmost quality and reliability of your packaging solutions.

Package Testing Standards FAQ

What is the ASTM?
ASTM stands for the American Society for Testing and Materials, now known as ASTM International. It is a globally recognized organization that develops and publishes voluntary consensus technical standards for a wide range of materials, products, systems, and services. ASTM standards are used across various industries to improve product quality, enhance safety, facilitate market access and trade, and build consumer confidence.

These standards are developed through a consensus process involving volunteers from various industries, governments, academia, and consumers who work together in technical committees to create and maintain the standards. ASTM International’s standards are widely used and accepted worldwide, serving as a common language for industries and helping to ensure quality, safety, and interoperability.

What is ASTM D642?
ASTM D642 is a standard test method for determining the compressive resistance of shipping containers, components, and unit loads.

What is ASTM D4169-16?
ASTM D4169-16 is a standard practice for performance testing of shipping containers and systems, evaluating their ability to withstand various distribution hazards.

What is the ASTM D4169 method?
The ASTM D4169 method is a practice for performance testing of shipping containers and systems, using a sequence of tests to simulate real-world conditions such as handling, transportation, and environmental exposure.

What is the difference between ASTM D4169-22 and D4169-16?
ASTM D4169-22 and D4169-16 are different versions of the same standard, with the -22 and -16 indicating the year of revision. There may be updates or changes in the testing procedures, equipment, or requirements between the two versions.

What is the difference between ASTM D4169-14 and -16?
ASTM D4169-14 and -16 are different versions of the same standard, with the -14 and -16 indicating the year of revision. The differences may include updates or changes in the testing procedures, equipment, or requirements.

What is the difference between ASTM D4169-16 and ISTA 3A?
ASTM D4169-16 is a standard practice for performance testing of shipping containers, while ISTA 3A is a test protocol from the International Safe Transit Association (ISTA) that focuses on packaged products weighing 150 lbs. (68 kg) or less. Both are designed to evaluate packages’ performance but use different test sequences and may have different specific requirements.

What is the sample size for ASTM D4169?
The sample size for ASTM D4169 varies depending on the type of container or packaging system being tested. The standard provides guidance on selecting representative samples, but it does not prescribe a specific number of samples to test.

What is the difference between ASTM D4169 and ISTA 1A?
ASTM D4169 is a comprehensive standard practice for performance testing of shipping containers and systems, while ISTA 1A is a test protocol from the International Safe Transit Association (ISTA) that focuses on packaged products weighing up to 150 lbs. (68 kg) under non-simulation integrity testing. ASTM D4169 covers a wider range of distribution hazards, whereas ISTA 1A is more focused on basic integrity testing, specifically vibrations and impacts.

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Package Testing Services: A Comprehensive Guide

Package testing services subject shipping containers to various tests, such as vibration, drop, compression, and environmental testing, to evaluate their ability to protect the contents from the point of pickup to the final destination. Shipping containers typically consist of cardboard boxes containing products like medical devices, consumer electronics, pharmaceuticals, industrial products, and online purchases. Factors influencing the package’s effectiveness include materials, product design, assembly methods, and environmental conditions.

Package Drop Test at DES

Delserro Engineering Solutions (DES) is a leading provider of package testing services, offering a wide range of testing solutions to ensure the safety and integrity of your products during transportation. Our experienced team of engineers and technicians utilize state-of-the-art equipment and adhere to industry standards to conduct comprehensive tests on your shipping containers. DES is committed to delivering accurate results and providing valuable insights that will help you optimize your packaging design and materials, ultimately reducing damage rates, minimizing returns, and increasing customer satisfaction.

Lab-based Package Testing

Package testing in a controlled laboratory environment adheres to international standards like ASTM or ISTA. This process assesses the shipping container’s durability, the packaging’s ability to protect the item, and the product’s resilience to shipping stresses, such as vibrations, drop shocks, and climatic conditions.

Why Perform Package Testing?

Package testing evaluates the design and materials of a package and its ability to protect the contents. By preventing damage during shipping, companies can:

• Minimize reshipping products
• Save staff time and resources by reducing return claims
• Increase sales through repeat orders from satisfied customers
• Boost profits from increased sales and fewer return shipping claims

Types of Package Tests:

Package vibration testing: Simulates transportation vibrations
Package drop testing: Replicates drops from rough handling
Package compression testing: Simulates load from stacking packages
Environmental testing of packages: Assesses the effects of altitude, temperature, humidity, sealing integrity, and exposure to moisture and extreme temperatures on the package system

Common package test standards are:

ASTM Package Test Standards: ASTM D4169 and ASTM D7386 simulate a distribution environment containing multiple events such as drops, vibration, compression loading, etc.
ASTM Vibration Test Standards: ASTM D999, ASTM D3580 and ASTM D4728 are procedures for vibration testing of packages only.
ASTM Environmental Package Test Standards: ASTM D4332, ASTM D6653, and ASTM F1980 are protocols for temperature and humidity conditioning, altitude testing and accelerated aging testing.
ISTA Package Test Standards: ISTA standards are designed around distribution environments that contain multiple events such as drops, vibration, compression loading, etc.
- ISTA Series 1: ISTA 1A, 1B, 1C, 1D, 1E, 1G, 1H
- ISTA Series 2: ISTA 2A, 2B, 2C
- ISTA Series 3: ISTA 3A, 3B, 3E, 3F
- ISTA Series 6: These are specialized procedures for Amazon, Sam’s Club and Fedex

In summary, package testing services play a crucial role in ensuring that your products arrive safely at their destination, maintaining customer satisfaction, and reducing the likelihood of costly returns. By adhering to industry standards and conducting a comprehensive evaluation of package materials, design, and environmental resilience, package testing services can identify potential issues and help you optimize your packaging strategy.

DES offers expert Package Testing services within our environmentally controlled, accredited laboratory. Please contact a professional if you have any questions.

Package Testing FAQs

How do you test packaging?

Packaging is tested using various methods such as vibration, drop, compression, and environmental testing in a controlled laboratory setting.

What is package-level testing?

Package-level testing involves assessing the performance and durability of a shipping container and its ability to protect the contents during transportation.

What is the function of package testing?

The function of package testing is to evaluate the effectiveness of packaging materials, design, and systems in protecting products during shipping.

Why is packaging testing important?

Packaging testing ensures that products reach their destination undamaged, reduces return claims, and maintains customer satisfaction.

What are the advantages of package testing?

The advantages include optimizing packaging materials, minimizing reshipping, saving staff time and resources, increasing sales, and boosting profits.

What are the 3 levels of packages?

The term “3 levels of packages” does not specifically apply to package testing. However, in the context of package testing, there are three main aspects: the shipping container, the protective packing materials, and the product itself.

What is product testing and packaging?

Product testing involves evaluating a product’s performance, quality, and durability under various conditions, while packaging refers to the materials and methods used to protect and transport the product. Package testing combines these concepts by assessing the effectiveness of the packaging in safeguarding products during shipping.

What is packaging integrity testing?

Packaging integrity testing evaluates whether the packaging can protect the sterility of a medical device or sealed food products during transportation and under different environmental conditions. After subjecting the packaged product to transportation or environmental stresses, it is then tested for seal strength or leak integrity.

By understanding package testing’s importance and various aspects, companies can ensure their products reach their customers in excellent condition, minimizing returns and boosting customer satisfaction.

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What is Space Simulation Testing?

Space Simulation Testing replicates the high altitudes and temperatures for items that are used in outer space, satellites, or rockets. Products that will be used in space or high altitudes must be able to endure combined environments of extreme temperatures and extreme low pressures.

Space is defined as an altitude more than 100 km (62 miles or 328,000 feet) above sea level. The pressure at this altitude is roughly 2.4 x 10^-04 to 4 x 10^-04 mbar (1.8 x 10^-04 to 3 x 10^-04 torr) [1]. Temperatures can be as cold as -80 °C. This is a very difficult environment for anything to survive. That is why Space Simulation Testing is essential!

Space simulation testing is performed in a specialized Thermal Vacuum Chamber or TVAC. TVACs are very specialized chambers that have a two-stage vacuum pumping system and a thermal plate. The vacuum pumping system typically consists of a roughing pump and a turbo molecular pump. The vacuum pumping system must be capable of achieving vacuums of 1 x 10^-04 torr and below. The thermal plate should be capable of constant or cyclic temperature control from -80 °C to +100 °C.

space-simulation-testing-chamber — *DES’s Thermal Vacuum Chamber (TVAC)*

Why Perform Space Simulation Testing?

Mission-critical equipment and components that are used in satellites or space systems are very expensive. They can take years to develop and launch. It is essential that space equipment is thoroughly tested not just to survive these extreme conditions, but it must also operate properly and be reliable. Failure during launch or operation in space is not an option! It is devastating and extremely costly. Satellites can cost over 150 million dollars. In addition, space simulation testing of components in a TVAC can expose issues before they are integrated into larger systems saving time and overall project cost.

Why Choose DES for Space Simulation Testing?

DES has the experience and accredited lab to perform validation of mission-critical components during Prototyping, Design Verification, and Qualification phases. DES’s TVAC can achieve high vacuum levels and apply extreme temperatures simultaneously with high vacuums. DES can also simulate the severe vibrations and pyroshocks that occur during a launch.

Our Space Simulation Equipment Capabilities Are:

High vacuum levels down to 10^-7 torr (1,000,000 Feet or 200 miles!)
Cyclic or constant temperature control from -100°C to +150°C
16 x 16 inch thermal plate
Multiple sealed access ports to allow products to be operational and monitored during testing including power, data, and RF lines
View window for visual monitoring
Digital vacuum pressure recording
Multiple thermocouples for recording thermal plate & product temperatures
[1] AFGL Atmospheric Constituent Profiles (0-120km)

thermal-vacuum-chamber-graph — Test Performed in DES’s Thermal Vacuum Chamber (TVAC)

Please contact us or call 610.253.6637 to discuss your project with an expert.

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What is the Difference Between Thermal Shock and Temperature Cycle Testing?

Our customers often ask, What is the Difference Between Thermal Shock and Temperature Cycle Testing? Both types of tests expose products to cycles between hot and cold temperatures. Both tests produce stresses caused by thermal expansion and contraction. In many cases, components expand and contract differently. This creates cumulative fatigue damage during each cyclic, which could result in a fatigue failure.

Thermal shock exposes devices to rapid temperature changes greater than 15°C/minute. Temperature cycle testing uses a transition rate less than 15°C/minute and is usually between 1 to 10°C/minute from our experience.

Continue reading What is the Difference Between Thermal Shock and Temperature Cycle Testing? →

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How to Make Your Product More Reliable Through Testing

At DES, we have tested many different kinds of products ranging from medical devices to aerospace products. We have performed numerous reliability tests and developed numerous accelerated life test plans. Many times, our customers ask us, “How do we make our products more reliable?” There are analytical methods and processes that can be used to improve product reliability. However, the focus of this article will be How To Make Your Product More Reliable Through Testing.

Continue reading How to Make Your Product More Reliable Through Testing →

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Delserro Engineering Solutions Featured in Assembly Magazine

DES president Gary Delserro is featured in an article published in Assembly Magazine on July 9, 2021. Titled “Accelerated Life Testing,” the article discusses different types of manufacturing life testing and quotes Gary with reference to highly accelerated life testing (HALT):

“Companies have reported savings in the millions after using HALT,” claims Delserro. “The test can accelerate a product’s aging process from actual months into test minutes, and it can help you discover weaknesses in your product during the design stage. Combined vibration, temperature and electrical stress variables, as well as internal fluid pressure, are typically used during HALT to induce failures and uncover fault points. By using combinations of loads, we can uncover design or manufacturing process flaws before they reach your customer.”

The entire article can be found on Assembly’s website.

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Delserro Engineering Solutions (DES) – Recent Projects (Spring 2021)

Recently, DES has been very busy working on multiple space and aerospace test programs. We can’t discuss too many details due to the sensitive nature of the products. Some highlights are:

Continue reading Delserro Engineering Solutions (DES) – Recent Projects (Spring 2021) →

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What Exactly is MIL-STD 810?

Mil Std 810 Test Procedure for military specification testing

MIL-STD 810 is a Department of Defense Test Method Standard for environmental engineering considerations and laboratory tests. It is the most popular Military specification used to conduct environmental testing of military products. It exists so as to ensure that products used for defense-related purposes meet very specific requirements with regard to ruggedness, durability, and performance. Given the fact that these products may be exposed to harsh or even extreme conditions, their reliability under stress is essential

Continue reading What Exactly is MIL-STD 810? →

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