Custom Test Development

We develop tailored experimental setups to investigate problems that cannot be addressed with standard testing methods.

From early-stage concepts to complex multi-parameter systems, we design and implement test solutions that enable reliable evaluation under controlled conditions.

From Idea to Experimental Validation

When standard methods are not sufficient, we work with customers to define and build new experimental approaches.

This includes:

  • Translating conceptual problems into measurable test setups
  • Designing and integrating custom hardware and instrumentation
  • Iterating on setups to achieve stable and meaningful results

Our approach is focused on making complex or previously untested concepts experimentally accessible.

Tackling Complex and Coupled Problems

Many real-world challenges involve multiple interacting effects that cannot be isolated easily.

We develop test setups to investigate:

  • Coupled thermal and fluid processes
  • Interaction between coatings and active systems
  • Multi-parameter dependencies under realistic conditions

These problems often require several iterations of design, testing, and refinement before meaningful results can be obtained.

Example: Hybrid Ice Protection System Evaluation

One example is the development of a test setup to evaluate evaporation efficiency of hybrid ice protection systems on aerodynamic geometries.

The setup included:

  • Multi-zone electrothermal heating with controlled power density
  • Integration of coating systems on representative geometries (e.g. airfoil sections)
  • Controlled exposure to water and airflow conditions
  • Automated control and data acquisition for repeatable testing

This allowed evaluation of how different coatings influence water evaporation and runback behavior under defined conditions.

The results provide direct insight into whether a system effectively prevents re-freezing in unprotected regions.

Example: Fluid adhesion characterization test rig

We developed a dedicated test rig to investigate fluid behavior on coated and inclined surfaces under realistic operating conditions.

This includes:

  • Evaluation of fluid run-off at defined inclination angles, such as 10° or 90°
  • Testing under different temperature conditions, for example 20 °C or -15 °C
  • Investigation of large-volume liquid behavior beyond standard contact angle methods
  • Analysis of the interaction between coatings and fluids over time

The setup combines a sample holder, weighing unit, collection cup, camera, LED lighting, computer unit and graphical user interface. With extended data and power cables, the test unit can also be operated inside a freezer while the computer remains outside.

These tests help fluid manufacturers improve their formulations and support coating manufacturers in optimizing surface paints for real operational conditions.

Example: Cold-Soak Fuel Frost Simulation

To investigate frost formation under cold-soak conditions, we developed a dedicated experimental setup combining thermal and environmental control.

The setup includes:

  • Active cooling of a heat sink using thermoelectric elements
  • Integration with airflow for controlled cooling
  • Exposure to humid ambient conditions
  • Surface temperature control down to low sub-zero temperatures

This enables investigation of frost formation and accumulation behavior on different coatings under realistic environmental conditions.

Flexible Engineering & System Integration

Custom test development often requires combining multiple disciplines.

We integrate:

  • Mechanical design and prototyping
  • Thermal systems and heating concepts
  • Sensors, control systems, and data acquisition
  • Custom software for automation and evaluation

This allows us to build complete experimental systems tailored to specific research or development questions.

Iterative Development Approach

Developing new test setups is inherently iterative. We build initial prototypes, evaluate them experimentally and refine the setup based on the results.

This approach enables us to investigate previously untested concepts, validate complex system interactions at an early stage and improve measurement accuracy and repeatability.

By generating reliable experimental data, the process helps reduce development risk and supports informed decision-making for innovative solutions.

Frequently Asked Questions

Yes, we design and implement custom setups when standard methods are not sufficient.

Setups can range from simple modifications to fully integrated multi-parameter systems.

No, custom test development is also used for application-driven development and validation.

This depends on complexity, but development typically follows an iterative process with early testing phases. Thanks to our agile approach, short turnaround times are possible; in urgent cases, we have built functional test systems in less than a month.