Multi-Axial (MAST) Testing Services

Accelerate Durability Validation with Reliable Multi-Axial Testing

In today’s fast-paced industries, components face complex stresses from vibrations, shocks, and environmental factors that single-axis tests simply can’t replicate. Whether validating automotive chassis accessories or ensuring military equipment withstands harsh conditions, delays in identifying failures can lead to costly redesigns and market setbacks.

At Reliable Analysis, our multi-axial testing (MAST) services provide a comprehensive solution, simulating real-world loads in six degrees of freedom (6DOF) to deliver accurate, accelerated results. Located in Madison Heights, Michigan, near Detroit’s automotive hub, we help suppliers and manufacturers achieve compliance and reliability faster. Ready to simulate road load data acquisition (RLDA) and beyond? Request a Quote Today.

Understanding Multi-Axial Testing and Its Critical Role

Multi-axial testing, often referred to as MAST testing, uses advanced simulation tables to apply forces and motions across multiple axes simultaneously. This includes three translational movements (X, Y, Z) and three rotational ones (pitch, roll, yaw), replicating the intricate dynamics encountered in operational environments. Unlike traditional vibration testing, MAST captures the full spectrum of stresses, making it essential for automotive durability testing RLDA and similar applications.

In the automotive sector, MAST ensures components like EV battery vibration testing withstand road-induced vibrations, reducing noise, vibration, and harshness (NVH) issues. Beyond automotive, applications extend to military for MIL-STD-810 vibration testing, industrial for seismic qualification testing, and commercial sectors like aerospace for component ruggedness. For instance, in civil engineering, MAST simulates earthquake effects on building utilities, while in defense, it validates generators under shock loads.

The importance of 6DOF vibration testing lies in its ability to accelerate lifecycle validation, compressing years of field exposure into weeks. This not only identifies weaknesses early but also supports data-driven decisions, such as fatigue life prediction. At Reliable Analysis, our MAST capabilities integrate environmental controls, ensuring tests align with real-world scenarios across sectors.

The Multi-Axial Testing Process at Reliable Analysis

Our MAST testing process is structured to provide precise, repeatable results tied to industry standards. We utilize 6-axis MAST tables (including 5′ × 7′ configurations) with 5.5 kip and 11 kip cylinders for precise force application. Integrated MTS FlexTest® controllers and RPC® Connect software deliver high-bandwidth, repeatable motion profiles. Additionally, our modular test components allow fast setup for any body-mounted assembly. Environmental conditioning (temperature, humidity, and infrared) is available in the same chamber. Here’s how it works step by step:

Initial Consultation and Setup

We begin by reviewing your component specifications and objectives. For automotive durability testing RLDA Michigan projects, this includes discussing road load data acquisition to gather field data using tools like our Head Acoustic SQuadriga data loggers (10-channel and 5-channel systems for sound and vibration measurement).

Data Acquisition and Profile Development

Field data is collected or provided, then processed to create durability drive files. This step removes non-damaging content, optimizing for efficiency. Standards like ISO 16750-3 guide mechanical load profiles for electrical components.

Simulation and Execution

Components are mounted on the servo-hydraulic MAST system, subjecting them to random vibration, sine sweeps, or shock replication. Environmental integration, temperature from -30°C to 90°C, humidity 30% to 95% RH, and infrared up to 105°C, enhances realism, as per GMW14124 for cycle testing.

Monitoring and Analysis

Real-time data acquisition tracks performance, with post-test analysis validating CAE modeling and predicting fatigue life. This ties into standards like ASTM D3763 for impact properties.

Reporting and Recommendations

Detailed reports include failure modes, compliance verification, and suggestions for design improvements. For EV battery vibration testing, this ensures safety under SAE J2380 guidelines.

In addition to dynamic 6DOF vibration, we perform static strength, cyclic loading, permanent set / deformation, and full fatigue testing on the same hydraulic rigs, giving you complete characterization of component integrity in one facility. This process minimizes downtime, with seamless transitions possible from buzz, squeak, and rattle (BSR) testing on our MB quiet shaker in an anechoic chamber to MAST durability, all under one roof.

Real-World Applications and Case Studies

Multi-axial testing applies across diverse sectors, delivering tangible benefits in reliability and performance.

• In automotive, MAST validates engine mounts, exhaust systems, and seats under complex loads. A Tier 1 supplier in Michigan utilized our automotive durability testing RLDA services to simulate pothole impacts on chassis accessories per ISO 16750. The test revealed resonance issues early, enabling redesigns that prevented field failures and accelerated time-to-market by 20%.
• For EV battery vibration testing, our setup replicates road conditions to assess safety and integrity. One client tested lithium-ion packs under UN38.3 vibration profiles, identifying structural weaknesses that could lead to leaks, resulting in enhanced designs compliant with ISO 12405.
• In military applications, MIL-STD-810 vibration testing ensures equipment durability. A defense contractor employed our multi-axial fatigue testing Michigan capabilities for generator validation, simulating transport shocks. The outcomes confirmed ruggedness, avoiding deployment issues.
• Industrial and commercial uses include seismic qualification testing for HVAC systems and agricultural equipment. An industrial manufacturer tested ship-mounted modules under IEC 60068-2-64 random vibration, uncovering vibration transmissibility problems that were resolved before installation.
• In aerospace, MAST assesses ride comfort and component performance. A case involved validating nonstructural elements per SAE J1211, where our 6DOF vibration testing detected NVH flaws, leading to smoother operations and regulatory approval.

These examples highlight how MAST reduces risks and costs, with our data processing extending to CAE validation for predictive insights.

Body-Mounted Components We Validate with MAST

Our 6DOF multi-axial systems are purpose-built for the full range of interior and exterior body-mounted components that experience real-road and service stresses. Typical parts we test include:

• Instrument panels (IPs) and dashboards
• Center consoles and cockpits
• Seats and seat structures
• Front-end modules (FEMs)
• Roof rails, crossbars, and sunroofs
• Mirrors and exterior lighting
• Lift gates, hood latches, and hitches
• Electrical modules and storage containers

These tests replicate operational loads, vibration, and motion to identify fatigue life, stiffness changes, deflection, strain, and failure modes, exactly what OEMs and Tier-1 suppliers need for both durability and BSR validation.

Why Choose Reliable Analysis for Multi-Axial Testing

As an A2LA-accredited lab in Madison Heights, Michigan, Reliable Analysis stands out for multi axial simulation Detroit projects. Our proximity to major OEMs like GM and Ford enables quick access and collaboration, with short lead times, often starting tests in days.

We offer broad capabilities, including multiple ED shakers and MAST systems for wide frequency and load conditions.

Additionally, our large-bed-plate reaction mass floor and multiple MAST rigs allow us to handle everything from single-axis checks to full 6DOF durability plus BSR evaluations without shipping parts between labs. This allows seamless workflows, such as BSR testing followed by vibration durability without delays.

Our consultative services guide standard selection; as a partner, we’ll walk you through ISO 16750 mechanical testing or GMW3172 testing lab requirements to meet specs efficiently.

Unlike generic labs, we emphasize institutional expertise in RLDA as a scope expansion tied to our vibration and fatigue scope, ensuring comprehensive solutions. Trust our reputation for accurate, actionable results that drive compliance and innovation.

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Frequently Asked Questions About Multi-Axial Testing

What is the difference between MAST testing and single-axis vibration testing?

MAST provides 6DOF simulation for realistic multi-directional stresses, ideal for automotive and military applications, while single-axis limits to one direction. Our system excels in capturing NVH issues per standards like SAE J2380.

How long does a typical MAST test take, and what are the lead times?

Tests range from days to weeks, depending on complexity. With our Michigan location, lead times are short—often under a week for setup, faster than national labs.

Can MAST integrate environmental conditions like temperature and humidity?

Yes, our 570 cu. ft. chamber supports -30°C to 90°C temperatures, 30-95% RH humidity, and infrared up to 105°C, aligning with GMW14124 for comprehensive exposure.

What standards does your MAST testing support for EV battery vibration testing?

We cover SAE J2380, ISO 12405, and UN38.3, ensuring safety and performance validation.

How does road load data acquisition (RLDA) tie into MAST?

RLDA collects field data to create accurate profiles for MAST simulation, predicting fatigue life and validating designs per JIS D 1601 or TS371-06-003.

Is MAST suitable for non-automotive sectors like military or industrial?

Absolutely, our capabilities extend to MIL-STD-810 vibration testing for defense and seismic qualification testing for industrial components.

What data analysis do you provide post-MAST testing?

We process data for CAE model validation, fatigue prediction, and durability drive files, offering insights beyond raw results.

Related Services

Enhance your MAST project with our accredited mechanical testing scope:

• Vibration Testing: Including random and sine profiles on ED shakers.
• Fatigue Testing: Servo-hydraulic for load/displacement control.
• BSR Testing Automotive: Buzz, squeak, and rattle in our hemi-anechoic room.
• Environmental Cycle Testing: Temperature, humidity, and thermal shock.
• Impact Testing: Multi-axial and Izod/Charpy methods.

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Standards Reference

Reliable Analysis performs MAST testing to these key standards, with dedicated pages for details:

• ASTM D3763: Puncture properties for plastics
• ISO 6603-2: Instrumented puncture impact for rigid plastics
• MIL-STD-810: Environmental vibration and shock for military
• SAE J1211: Robustness for automotive electronics
• ISO 16750-3: Mechanical loads for vehicle equipment
• GMW3172: E/E component durability (OEM requirements also incorporate static strength and permanent set evaluations)
• SAE J2380: EV battery vibration
• IEC 60068-2-64: Broadband random vibration
• ISO 12405: Lithium-ion battery packs
• JIS D 1601: Automobile parts vibration
• UN38.3: Lithium battery transport
• GMW14124: Environmental cycles
• FLTM BO 116-01: Interior weathering
• TS371-06-003: Servo-hydraulic fatigue
• PF.90223.9.3.2: Multi-axial fatigue with environmental integration

Don’t let uncertainties delay your project, partner with Reliable Analysis for MAST testing that delivers confidence and compliance. Get Your Quote Now.