Engineered Test Setups for Complex Products
PEKO provides custom test fixture design, test stand development, and production-ready test stations for complex OEM manufacturing programs. Developed in coordination with manufacturing test procedures, each custom test fixture is engineered around the unit under test (UUT), test method, required measurements, production environment, and operator workflow.
Capabilities range from compact functional test fixtures and mechanical test fixtures to custom test rigs, test stands, and larger production stations incorporating electrical, pneumatic, fluid, instrumentation, and safety features. PEKO supports the engineering, fabrication, assembly, integration, and validation needed to move test hardware into practical manufacturing use.
Custom Test Fixture Design Considerations
PEKO’s test fixture design process considers how the unit under test will be positioned, connected, evaluated, and handled within the manufacturing environment.
UUT Positioning & Test Interface
PEKO’s engineers evaluate the product geometry, test sequence, operating conditions, required measurements, and acceptance criteria to define a controlled interface between the UUT and the test setup. A custom test fixture may incorporate:
- Precision locating, alignment, and workholding
- Electrical, pneumatic, vacuum, hydraulic, or fluid connection points
- Mechanical loading, actuation, motion, or restraint features
- Access to calibration, adjustment, and measurement locations
- Contact and loading features designed to protect the product
These elements help position and connect the product consistently without introducing unnecessary variation into the test results.
Test Hardware & System Integration
PEKO integrates the hardware required to perform, monitor, and support the test. Depending on the application, the fixture or test stand may include:
- Sensors, probes, instruments, and data-acquisition interfaces
- Controls, indicators, switches, and interlocks
- Pneumatic, vacuum, fluid-handling, or utility components
- Structural frames, enclosures, and load-bearing supports
- Connections to standalone instruments or broader test systems
For larger products, test stand design may also address structural stability, equipment placement, utility routing, and access for setup, calibration, and service.
Production Use & Ongoing Support
PEKO designs fixtures and test stations for practical, repeatable use within the intended production environment. Considerations may include:
- Loading, unloading, and product changeover
- Ergonomic access and operator visibility
- Defined sequences, guarding, and error-proofing
- Cycle-time and throughput requirements
- Maintenance, calibration, and replaceable wear items
- Product revisions, interchangeable tooling, and duplicate stations
Addressing these requirements during test fixture development helps move the equipment from an engineering setup into sustained production use.
Custom Test Fixtures, Rigs, Stands & Stations
PEKO develops test hardware in configurations matched to the product, verification requirements, production environment, and intended use.
- Functional and mechanical test fixtures support quality-at-the-source verification of components, subassemblies, and completed products within PEKO’s contract manufacturing operations or customer production lines.
- Custom test rigs support engineering investigations, feasibility evaluations, process characterization, repeated-cycle testing, and other specialized applications.
- Test stands provide the structure, utilities, instrumentation, and access needed for larger products, higher loads, or more involved test procedures.
- Production test stations combine the UUT interface, operator controls, safeguards, and supporting hardware required for repeatable manufacturing execution.
These configurations may operate as standalone test setups or provide the physical UUT interface within larger Automated Test Equipment. In an automated system, the fixture positions and connects the product while the ATE manages test sequences, controls, instrumentation, measurements, and data collection.
PEKO also applies test tooling development within its own machining and assembly operations to monitor process performance, validate improvements, and support more consistent production results.
Validating Test Hardware Performance
PEKO can establish a test validation matrix to confirm that a completed fixture, test rig, test stand, or test station performs as intended before entering service. Depending on the program, validation may confirm:
- Repeatable UUT positioning, connections, and measurements
- Correct response under known-good, known-failure, or simulated conditions
- Proper operation of controls, safeguards, and operator interfaces
- Completion of required acceptance records and documentation
Periodic revalidation may also be performed to “test the tester” and identify wear, damage, connection issues, or other changes that could affect verification results. The validation method, frequency, acceptance limits, and documentation are based on equipment usage, production risk, test requirements, and customer expectations.
Why Choose PEKO for Custom Test Fixtures
PEKO provides custom test fixture design and manufacturing as part of a broader test development, production-readiness, and manufacturing-execution capability—not as an isolated fixture fabrication service. OEMs work with PEKO for:
- Engineering, fabrication, assembly, integration, and validation through one manufacturing partner
- Test fixture development coordinated with manufacturing test procedures and production workflows
- Mechanical, electrical, pneumatic, fluid, controls, and instrumentation expertise
- Support for fixtures used within PEKO’s contract manufacturing programs or deployed in customer production environments
This integrated approach helps align the physical test interface with the procedure, operator workflow, and production environment in which it will be used.
Related Manufacturing Testing Services
Depending on program requirements, PEKO can also provide:
- Test Engineering Services to establish the verification strategy, technical approach, required measurements, and acceptance criteria.
- Manufacturing Test Development to convert requirements into repeatable procedures, work instructions, and production test methods.
- Functional Testing & Product Verification to perform approved testing and document product performance during manufacturing.
- Automated Test Equipment to combine custom test fixtures with automated controls, instrumentation, test sequences, and data collection.
- Life-Cycle Testing to evaluate performance during repeated operation, extended use, or defined durability conditions.
FAQs About Custom Test Fixture Development
- What information does PEKO need to begin fixture development?
- Useful starting inputs may include product drawings or CAD models, test requirements, required measurements, acceptance criteria, anticipated production volumes, cycle-time goals, operator considerations, and information about available instruments or utilities. PEKO can review the available inputs and identify any additional information needed to define the fixture scope.
- How does PEKO determine whether a fixture, test stand, or test station is appropriate?
- The equipment format depends on factors such as UUT size and weight, structural loads, test complexity, required instrumentation, utility needs, operator interaction, and whether the equipment will support engineering evaluation or routine production.
- Can PEKO improve or replace an existing test fixture?
- Yes. PEKO can evaluate fixtures that are difficult to operate, no longer repeatable, incompatible with product revisions, or unable to support current production requirements. Support may include modifying specific features, replacing worn or obsolete components, or developing a new production-ready fixture.
- Can customer-specified instruments and components be incorporated?
- Yes. PEKO can design around customer-approved instruments, connectors, sensors, controls, safety components, and other specified hardware. The required mechanical, electrical, and utility interfaces can be incorporated into the overall test fixture design.
Develop a Production-Ready Test Setup
PEKO provides custom test fixture design, test stand development, and production-ready test stations that support repeatable product verification and reliable manufacturing execution. Contact PEKO to discuss the fixture, test stand, or test station requirements for your manufacturing program.