Universal testing machines are getting smarter. New developments in artificial intelligence (AI), automation, and sensors are upgrading these common quality assurance tools. For manufacturers, this means more precise data and faster testing. But it also means adapting to new technology and training staff to use it.

"There continues to be improvements in electro-mechanical systems that are affording more accuracy and control," said Carl Bramley, materials product manager at PPT UK Ltd. "Increased flexibility to govern how loads are applied to test samples advances the potential complexity of operations of quality assurance test methods and hence, real-world relevance."

More precision and control allow for more realistic testing of materials. And combining visual data with physical measurements gives testers more valuable information.

Recent advancements in universal testing machines include higher accuracy, integration of automation capabilities, and improved safety features, said Stephen Sobchuk, senior product manager, Instron. "These changes help companies test faster, reduce errors, and ensure operator safety," he said.

Operators can now integrate testing data with IT systems, which has improved data management in quality testing. Amid growing concerns about data integrity and regulatory compliance, this integration has "provided better security and traceability of test data," Sobchuk said.

Testers Get Smarter with AI Integration

Artificial intelligence and machine learning are carving out new possibilities for data analysis and user interaction. For example, AI is improving the capabilities ofmaterial testing beyond what was previously possible with traditional methods. "AI is helping in data analysis, collating test and performance information from multiple sources and scrutinizing it to predict material performance with greater accuracy," Bramley said. "This feedback of knowledge refines test processes and the way calculations and results are presented."

In the right hands, AI can lead to smarter systems that can learn from vast amounts of testing data, identify patterns, and make predictions that human operators might miss.

"With all the data that comes from materials testing machines, AI can enhance a testing lab’s ability to identify trends or patterns, helping companies address quality issues more quickly and reducing the likelihood of bad product shipping," Sobchuk said.

AI also makes testing machines easier to use. It can add voice commands and virtual assistants to testing machines, making them simpler to operate. "AI can be utilized to improve the user interface, by providing intelligent assistance, such as natural language processing to facilitate voice interaction with the tester or incorporating virtual assistants to help users navigate testing protocols," said Evan Moreira, strategic applications engineer, Shimadzu Scientific Instruments.

Challenges and Solutions in Training, Safety

New testing machines are powerful but may come with a learning curve. Training workers to operate them can be challenging. For example, organizations need ongoing training programs to keep staff skilled with new testing machines, as knowledge can be lost when employees leave.

"Training should be imparted at point-of-sale, be comprehensive, and be relevant to the application for which the universal tester has been selected," Bramley said. "Additional top-up training is also made available, but issues arise with retention in trained staff and losing that testing knowledge."

Collaboration between equipment manufacturers and educational institutions can help address the skills gap in materials testing, Bramley said. Testing machine manufacturers should consider working with schools and universities to give students hands-on experience, easing the transition from education to professional work. This encourages "practical, hands-on experience for students (and research staff), and can provide a solid grounding when transitioning into a professional career in industry," Bramley said.

Machine makers are designing simpler interfaces to help companies deal with high staff turnover and reduce mistakes in testing.

"A lot of our customers tell us that retaining employees is a big challenge, which means they are constantly onboarding and training new people to operate their testing systems," Sobchuk said. To address this, manufacturers are focusing on making systems more user-friendly. "Giving lab managers the ability to build out guided workflows for each test method helps eliminate guesswork, missed steps, and costly errors," Sobchuk added.

Safety is another issue. In response, manufacturers are prioritizing user safety by making it more intuitive and visible in their latest equipment designs. "At Instron, we’ve built safety coaching into all of our latest generation 3400 and 6800 Series universal testing systems to provide clear visual feedback about the system status at all times – indicating when the system is in a safe setup mode and when to exit the test space," Sobchuk said.

Ergonomics is also receiving increased attention. As the industry focuses on operator well-being alongside machine performance, improving the physical design of testing equipment has direct benefits for worker health and safety.

"Machines with ergonomic designs will reduce uncomfortable positions for operators and result in fewer workplace injuries," Sobchuk added.

New testing machines can do more complex tests on advanced materials, Moreira said.

Modern machines can use multiple sensors at once, allowing for more detailed analysis of complex materials. Because advanced materials often need more than just basic strength testing, multiple sensors can measure different properties simultaneously, enabling more comprehensive testing in a single setup.

Automation, New Tech Expand Testing Options

Individuals often have misconceptions about automation being complex and expensive, when modern automated testing systems are actually quite varied, Sobchuk said.

Options range from simple automated tools to fully robotic systems, which makes automation more accessible to a wider range of users.

"When you say the word ‘automation,’ a lot of people think of big robots that are cost-prohibitive, take up a lot of space, and require extensive programming skills to operate. But this is no longer the case," he explained. "Today, automation for universal testing systems is offered on a spectrum that ranges from simple automated specimen measurement devices to fully robotic systems – with a lot of options in between."

The rise of new industries and materials is also driving innovation in testing equipment.

For example, the electric vehicle battery market continues to grow and evolve, necessitating a lot of innovation from testing system manufacturers, Sobchuk said. This includes developing new methods for handling difficult materials like thin films and foils, as well as addressing safety concerns in testing live batteries.

Cloud-based data sharing across industries and between suppliers and manufacturers is another emerging trend. "One version of the truth, available to internal company functions and trusted partners, facilitates a less siloed mode of operation," Bramley explained.

Optical measurement techniques, specifically digital image correlation, are becoming more common in testing. This technique allows for detailed mapping of sample strain, Moreira said. The result is a more detailed understanding of how materials behave under stress.

Rising Quality Standards Drive Smarter, More Versatile UTMs

As quality standards continue to rise, testing equipment is evolving to be more precise, versatile, and user-friendly. Bramley predicts that testers will become more accurate to meet stricter standards, and testing methods will get more complex to better mimic real-world conditions. To keep up with regulations and improve repeatability, organizations need flexible software and automation.

Moreira echoes this. As demand for higher quality standards grows, users may need to learn a wide variety of fixturing and software testing methods. "Intuitive software and easy-to-reconfigure hardware can help users run a wide variety of testing standards with accuracy and confidence," Moreira added. And, embedding prebuilt as well as customized calculations in the test machine software can help with newer, complex testing methods, he said.

Traceability is becoming more important, requiring better security and user tracking, Sobchuk said. Thankfully, IoT technology is allowing centralized management of testing settings across global organizations.

"In the context of universal testing systems, this means greater control over security, user permissions, electronic signatures, and a log or audit trail that tracks system level usage such as logins, modifications to test methods, file deletions, etc.," Sobchuk said.

Advancements in universal testing machines reflect a broader trend of digitalization and automation in manufacturing and quality control, experts say. As testing becomes more sophisticated, it's likely to influence product design, material selection, and regulatory standards across multiple industries.