Spacecraft components, high-end medical devices, new‑energy batteries, precision instruments—these products typically have design lifetimes of ten years or more, with failure rates required to be as low as one in a million.
However, behind this outstanding reliability lies a formidable verification challenge for engineers:
“Zero failures” at the test site: Despite a massive investment—deploying over a hundred prototype units and subjecting them to months of rigorous testing—no single unit exhibited a fault, leaving the data inconclusive and rendering any meaningful evaluation impossible.
Time costs are not something you can afford to wait for: waiting for several failure points could extend the trial period to several years, and the market window waits for no one.
Sample costs are high: each sample is expensive, and conducting extensive testing not only consumes significant time but also imposes a financial burden that many cannot afford.
The traditional “test‑fail‑analyze” paradigm has reached an impasse. We urgently need a modern solution that is smarter, more efficient, and more cost‑effective.
Say goodbye to waiting and expiration—welcome a new era of “seeing” through degradation.
A reliability assessment solution based on performance degradation, designed to help you break free from the constraints of small sample sizes and zero‑failure scenarios. Our core principle is this: no longer do we have to wait in vain for the “moment of failure”; instead, we continuously monitor the “aging” process.
1. Precisely Capturing “Aging” Signals—Performance Degradation Data Modeling
We use high-precision sensors to perform continuous, real-time monitoring of the product’s key performance parameters (KPCs).
For batteries, we monitor their capacity fade curve and internal resistance growth trajectory.
For bearings, we analyze the energy variations in their vibration signals and the trends of wear particles.
For LEDs, we track the degradation path of their luminous flux.
By establishing degradation models that describe how these performance parameters evolve over time or across cycles, we can accurately predict the moment when performance will exceed the failure threshold, thereby enabling the scientific calculation of a product’s life‑cycle and reliability metrics even with very limited samples and zero observed failures. This makes reliability both “visible” and “predictable.”
2. Accelerated Testing: Doubling Efficiency—High-Precision Accelerated Test Design
Relying solely on the passage of natural time is undoubtedly far too inefficient. We deeply integrate the Physics of Failure:
Accurately identify the product’s sensitive stressors, such as temperature, voltage, mechanical load, and humidity.
Based on classical physical failure models such as the Arrhenius and Coffin–Manson models, a scientifically sound accelerated testing profile is designed.
Accelerated stress testing is used to rapidly acquire degradation data, which is then extrapolated to normal operating conditions via a physical model to accurately assess product lifetime.
This is not merely an efficiency revolution; it is also a profound insight into the mechanisms of product failure.
Solution Value: Empowering High-End Manufacturing
Significantly shortens the timeline: Life‑cycle validation that would normally take several years can now be completed in just a few months—or even weeks—enabling faster time‑to‑market.
Ultimate cost savings: The required sample size is significantly reduced, directly lowering both the experimental and material costs.
In-depth mechanistic insights: Beyond identifying “when” a product fails, we can also analyze “why,” providing clear guidance for design improvements and enhancing inherent reliability.
Applicable Fields
This solution has been successfully applied to:
New energy vehicles: Verification of the cycle life and durability of power battery packs, drive motors, and BMS.
Aerospace: Long-life assessment of airborne equipment, aircraft engine blades, and satellite components.
High-end healthcare: Durability and stability testing of medical imaging equipment and implantable medical devices.
Precision Industry: Research on Wear and Fatigue in Industrial Robot Reducers, Sensors, and High-End Bearings.
We firmly believe that reliability should not be a “black box,” but rather a transparent process that is observable, analyzable, and optimizable.
If you’re grappling with the challenges of validating high‑reliability products, and if you want to unlock the value of innovation faster and at lower cost, our solutions are exactly what you need.