Full Vehicle Durability Testing

Overcome vehicle performance challenges with comprehensive durability testing that precisely replicates real-world conditions in a controlled laboratory environment. Element's advanced simulation technologies—including unique frame bending capabilities—detect potential defects early, reduce risk exposure, and provide critical insights into how your vehicles and components will perform during actual use. This accelerated approach brings safer, more reliable products to market faster while ensuring they meet expected service life requirements.

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What is Full Vehicle Durability Testing at Element?

Full vehicle durability testing determines how vehicles and components perform under various stress conditions to predict expected vehicle lifespan. During testing, we subject the vehicle to stress-inducing inputs (variations in loads, road characteristics and environmental conditions), on an accelerated testing schedule that replicates years of wear, then assess how such inputs affect the vehicle and its components. Our testing detects defects early in the development process, validates designs, and supports innovation while reducing risk exposure across vehicle systems and components.

Two Element testing experts in laboratory safety equipment ready for testing

What Can Element Offer You For Full Vehicle Durability Testing?

Key tests offered

Element's durability testing recreates complex stress patterns your vehicles experience in the field. Our full spectrum of vehicle durability testing services encompasses a variety of mechanical, electrical, and electromechanical tests for all vehicle classes.

We perform:

Dynamics testing

Impact testing
Multi-Axial Simulation Table (MAST) testing
Real-time simulation
Salt spray and salt fog testing
Shock testing
Spindle-coupled road simulation
Vibration testing
Thermal testing
Tire-coupled road simulation
Weathering testing
Seven-channel engine cooling module testing
Tire coupled 4 & 6-post road technologies
Road load data acquisition and analysis Methods and solutions offered

Element's approach integrates road load data analysis with controlled laboratory conditions for unmatched testing precision. We subject vehicles to stress-inducing variations in loads, road characteristics, and environmental conditions on accelerated schedules that simulate years of wear.

Advanced simulation techniques
Unlike conventional testing, our methods include specialized capabilities like seven-channel engine cooling module testing specifically for when MAST testing is not sufficient. This approach induces frame bending and twisting—real-life stresses that cannot be recreated by other testing methodologies due to their inherent inability to bend or twist frames. This unique approach provides insights unavailable through standard testing and helps you develop more durable products that withstand complex real-world stresses. It uses road load data analysis (RLDA) results collected in real time to recreate road conditions in the lab for analysis.

Components and products we test

Our testing capabilities encompass both complete vehicles and critical subsystems. We evaluate full vehicles, partial vehicle systems, and individual components to provide comprehensive performance data that helps manufacturers ensure the integrity of the vehicle and project its minimum expected service life.

Complete vehicles and vehicle systems
Chassis and suspension components
Powertrain mount systems
Steering systems
Exhaust systems
Trailer hitches
Engine cooling modules and systems
Passenger cars
Light, medium and heavy truck
Transport trailers
Off-highway equipment
Military vehicles,
School and transit buses
Commuter coaches

Cutting-edge equipment we use

Our laboratories are outfitted with advanced testing equipment and road simulators that replicate the most representative driving profiles, road surfaces, and weather conditions. Our systems precisely coordinate to reproduce the exact acceleration responses, twists, and bends your products will face in real-world applications.

Real-time multi-axial simulators
Tire-coupled 4 & 6-post road simulators
Seven-channel cab shake simulator
Environmental chambers for weathering
Road load data acquisition systems
Multi-Axial Simulation Tables (MAST)
Servo-hydraulic testing equipment

The seven-channel simulator is made up of:

Seven servo-hydraulic controlled actuators
Four vertical actuator inputs
Two lateral actuator inputs
One longitudinal actuator input

Which labs offer this service

Our expert team operates from automotive hubs to give you convenient access to our expert capabilities. Find your nearest Transportation lab on our Locations Page.

Standards we test to and components we test

These are our most prevalent requests. Don't see what you're looking for? Contact us!

We perform durability tests for suppliers and OEMs within the transportation industry according to technical specifications, industry standards, national and international standards. These include:

MIL-STD-810
IEC 60068-2-1, -2, -6, -14, -27, -29, -30, -32, -38, -52, -64, -74, -78 and others
JDQ 53.3
ASTM D4169
GMW 3172
RTCA DO-160G
ANSI C136.31
ASTM D4728
GMW 8287
USCAR 21
ASTM D999
JIS D1601

Your Challenges, Our Solutions

Unpredictable real-world conditions

Our advanced simulation technologies accurately recreate in-service forces and motions your vehicles experience in the field, giving you critical insights into performance under the complex stresses of actual use conditions. Our methods include specialized techniques like seven channel testing for frame-induced stresses.

Delays due to late-stage defects

With accelerated durability testing that subjects vehicles to stress-inducing inputs on compressed timelines, we help you detect potential defects early in development while collecting data critical to the design validation phase. Our testing helps project minimum expected service life with confidence.

Complex stress interactions

Our multi-channel testing systems simultaneously apply multiple stress vectors to your vehicles and components, identifying potential weak points that single-direction testing might miss. From multi-axial simulation to specialized seven-actuator systems, we create comprehensive stress profiles matching actual use conditions.

Development timelines compressed

Element's comprehensive testing methods deliver years of equivalent field experience in condensed timeframes, allowing you to validate durability without extending product development cycles. Our accelerated testing protocols maintain accuracy while significantly reducing time-to-market.

Why Choose Element

Element testing specialist standing among environmental test chambers in product testing lab

Comprehensive vehicle testing capability

Our advanced simulation technologies deliver testing depth across all vehicle classes, from passenger cars to heavy equipment and specialized vehicles.

Multi-level evaluation options

We offer testing flexibility at full-vehicle, subsystem, or component levels to meet your specific validation requirements and budgetary considerations.

Specialized stress simulation

Our unique testing capabilities, including seven channel engine cooling module testing, replicate critical stresses that cause real-world failures but are missed by conventional methods.

Proven industry partnership

We work with major vehicle manufacturers and suppliers to create customized solutions that support shorter product life cycles and faster market entry.

30+
years transportation industry experience

Trusted partner to leading manufacturers

12+
vehicle testing technologies

Complete multi-directional stress simulation

30+
years transportation industry experience

Trusted partner to leading manufacturers

Element testing engineer operating salt fog chamber for product environmental testing

But don't just take our word for it

See what others say about partnering with Element.

Element has been very accommodating of tight schedules and provided very thorough test reports.
Alejandro Cordoba,
Lear Corporation Southfield

Frequently asked questions

How does full vehicle durability testing differ from component-level testing?

While component testing provides valuable data about individual parts, full vehicle testing evaluates how entire systems interact under stress. This holistic approach reveals issues that might be missed in isolated component testing, such as interface problems between subsystems or cumulative stress effects that emerge only at the vehicle level.

When would I need seven-channel engine cooling module testing instead of standard MAST testing?

Standard MAST testing cannot recreate certain real-world stresses, particularly frame bending and twisting that affect cooling modules. Our seven-channel testing is specifically designed to induce these frame-related stresses, providing critical durability insights for cooling modules that would be missed with conventional testing methods. This is essential when you need to verify how your cooling module will perform under the complex stresses of actual vehicle operation.

Explore our global network of labs and find your nearest location

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