Testing &
Inspection.

Why this is relevant — Test-bench programs apply the same alternative component validation verification discipline shown in this thermal imaging case.

Facing a supply chain shortage for a critical IPEX connector on a micro-coax assembly, an alternative component needed to be sourced and validated for a European sensing equipment manufacturer.

Challenge

Original IPEX connectors were out of stock, threatening the continuity of supply for the AWG#40 micro-coax cable assembly, with the customer explicitly stating it was impossible to receive cables with the correct connectors.

Solution

Sourced an alternative connector, manufactured 10 sample assemblies, and submitted them to the customer's technical team for rigorous functional testing and validation.

Result

The alternative connector samples passed the customer's testing with an approval, allowing production to continue and resolving the supply chain bottleneck.

Why this is relevant — Test-bench programs apply the same rapid prototyping verification discipline shown in this energy case.

A US energy management company needed initial physical samples to validate a complex custom overmolded power cable design before committing to production tooling.

Challenge

Standard production molds for overmolded cable assemblies are costly and time-consuming, creating a barrier for early-stage NPI validation requiring only a handful of units.

Solution

Proposed a rapid prototyping approach using silicone molds instead of hard tooling, allocating 50 pieces of raw material to produce an initial batch of 5 sample units for testing.

Result

Delivered functional samples within a 3-4 week turnaround (including 2 weeks for silicone mold creation), enabling the customer to proceed with physical testing and design iteration without upfront hard tooling investment.