High-Temperature Functional Test Fixture
This case study outlines the story behind a specialist high-temperature functional test fixture developed in our Shanghai Factory.
Specialised High-Temperature In-Line Functional Fixture
A long‑standing automotive customer approached Forwessun with a requirement for a specialised Functional Test (FCT) fixture capable of operating inside a high‑temperature chamber. As a repeat customer, they were already familiar with Forwessun’s engineering capability and trusted us to deliver a robust solution for an environment far beyond standard fixture conditions.
Contents
The Challenge
The customer needed to perform an environmental “aging” test on their PCBA, a process designed to simulate long‑term wear by exposing the electronics to extreme temperatures over extended periods. This type of testing is essential in the automotive sector, where electronic assemblies must remain reliable throughout a vehicle’s lifetime.
A regular test setup would not withstand the 110 °C chamber environment as standard fixture materials cannot function properly under these conditions.
Without a fixture engineered for high‑temperatures, the customer risked inconsistent results and an inability to validate long‑term durability of their automotive PCBA.
The Solution
Forwessun developed a fully custom high‑temperature Functional Test Fixture engineered specifically to operate reliably inside the customer’s 110 °C chamber. From the outset, the design focused on material resilience, electrical stability, and long‑term mechanical integrity, ensuring the fixture could withstand repeated thermal cycles without distortion or performance issues.
Our engineering decisions delivered a robust, high‑precision fixture capable of performing consistently in a demanding thermal environment, giving the customer a reliable platform for validating the long‑term resilience of their automotive PCBA.
Heat Resistant Materials
Special‑grade heat‑resistant G10
Unlike standard G10, this enhanced material maintains structural integrity at elevated temperatures.
High‑temperature‑rated wiring
Designed to retain insulation and conductivity under thermal load.
Heat‑resistant test probes
Capable of maintaining spring force and electrical performance at 110 °C.
Temperature‑stable fasteners and hardware
To prevent loosening or deformation inside the chamber.
Custom Mechanical Design
The fixture was engineered to fit exactly within the customer’s heat chamber dimensions, ensuring safe clearance, correct airflow, and stable positioning during the aging test.
Functional Test Integration
The fixture enabled the customer to run a range of tests while the PCBA was under heat stress, including:
- Power‑on verification
- Signal and communication checks
- Component‑level functional tests
- Monitoring for thermal‑induced failures
This allowed the customer to validate real‑world reliability for environments where electronics may experience high temperatures.
The customer received a durable, high‑precision fixture capable of performing consistent functional testing inside a 110 °C chamber, a level of reliability not achievable with standard materials or designs. This solution enabled them to carry out accurate, long‑term aging tests without any fixture degradation, ensuring their PCBAs met stringent automotive reliability standards.
The use of stable, heat‑resistant materials delivered repeatable test results throughout extended thermal cycles, while the fixture’s custom dimensions provided a perfect fit within the chamber, maximising safety and ease of use.
The project reinforced a strong ongoing partnership with a customer who values Forwessun’s ability to engineer dependable solutions for demanding test environments.
Contact Us
At Forwessun, we pride ourselves on delivering reliable, high-quality solutions that help our customers bring products to market faster and with confidence. This case study demonstrates our commitment to precision, quality and collaboration in developing test solutions that drive real business value.
Get in touch today and let our team of experts support you and your next project.
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Our work is supported by over 40 test engineers globally, bringing practical expertise in fixture design and manufacturing integration. We focus on understanding each client’s production environment and building fixtures that work reliably within it.
