At MCE, our Engineered Systems Group (ESG) designs and builds custom fatigue and validation platforms for Tier I and II suppliers who can’t afford failures. From shock absorbers to hydraulic valves, our automated systems deliver repeatability, traceability, and speed.
The modern vehicle is more complex than ever before.
As electric vehicles (EVs), ADAS (advanced driver-assistance systems), and lightweight materials reshape vehicle architecture, component performance requirements are evolving faster than traditional testing setups can manage.
Tier I and II suppliers face the brunt of this evolution.
OEMs now expect faster validation cycles, stricter traceability, and 100% verification of part reliability due to the increasing complexity of mechanical and electrical systems. Each new model or model upgrade can come with shorter timelines, tighter tolerances, and no room for failure in the field.
These requirements are often outlined in OEM quality mandates such as IATF 16949 and the Production Part Approval Process (PPAP).
Manual or semi-automated testing systems can no longer meet these standards. Manual testing introduces operator variability, slows throughput, and makes it difficult to detect early fatigue or intermittent performance issues. Even minor inconsistencies in test load, timing, or environmental factors can skew results and put production schedules at risk.
That’s why leading suppliers are turning to custom, fully automated testing systems that replicate real-world stress conditions and ensure precision backed by data.
Reliable component testing is essential for automotive manufacturers. An automated test system finds defects earlier, faster, and with higher coverage — before it reaches the consumer.
Let’s break down some of the direct and indirect costs of inadequate testing:
Industry reports from Warranty Week show U.S auto parts manufacturers paid over $2 billion in warranty claims and $2 billion in accruals in 2024. This is cash either paid out or set aside to repair or replace defective parts that escaped quality control.
High recall problems can trigger civil penalties, consent orders, and even class-action exposure, resulting in costs exceeding repair and replacement.
Without proper component testing, manufacturers often experience higher production costs, engineering rework, higher scrap rates, more defects, and increased warranty expense. Manufacturers can cut costs by reducing scrap and waste when they invest in quality improvement measures like automated test systems.
Faulty parts or late detection can cause unplanned downtime and production stoppages. When continued, this can result in redesign or delayed product launches and missed revenue opportunities.
Other direct and indirect costs include:
Every testing challenge is unique. That’s why MCE builds custom platforms designed around each customer’s components, materials, and performance targets.
Our systems combine mechanical, hydraulic, and electronic design expertise to simulate real-world use cases, right down to the forces, frequencies, and failure modes your parts commonly experience on the road.
When a commercial mower manufacturer needed to validate its frame and weld durability, MCE designed a four-actuator fatigue system that simulated curb strike and terrain vibration up to 5 Hz. The result was a platform capable of destructive testing, allowing engineers to validate welds, frame stiffness, and overall structural endurance before production.
The same approach applies to automotive applications. Whether it’s a steering component, suspension control arm, or battery tray, these systems replicate real-world dynamics in a controlled lab environment. They turn what used to be guesswork into data-driven science.
Building a reliable test system takes more than hardware. It takes a deep understanding of how components behave, OEM requirements, and how suppliers can meet compliance.
That’s where we come in. MCE offerings include:
Our team works as an extension of your own.
We can assist in managing the process from CAD modeling and fixture design to Programmable Logic Controller (PLC) and Human Machine Interface (HMI) programming. That means faster turnaround, better communication, and improved integration between systems.
Consistency is the foundation of good data. Automated test sequences eliminate operator error, control every test parameter, and ensure every part is tested under identical conditions.
Our platforms support compliance with IATF 16949 and PPAP documentation, along with OEM-specific validation protocols.
Every system we build integrates data systems and reporting tools tailored to your workflow, whether Excel or custom formats. This traceability is essential for warranty defense and continuous improvement programs.
Our systems are built with people in mind. We design for safe and quiet operation on the factory floor or in quiet lab environments, with options like custom guarding, dead-man switches, and vacuum degassing for fluid systems.
We understand the pressures that Tier I and II suppliers face. Tight timelines, shared resources, and the need for consistent testing is critical. Our modular platform designs can be standardized and replicated across multiple sites, for consistency no matter where you operate.
Our custom test systems are built for automotive applications, including:
Whether you are testing metal, plastic, or composite components, we design platforms that apply realistic loads, measure responses precisely, and give you the data you need for confidence in your parts.
As vehicles evolve, so must the tools we use to test their reliability.
Whether you're developing next generation steering systems, validating EV subassemblies, or running high-volume quality assurance programs, MCE can design the test solution that delivers faster results, higher confidence, and full traceability.
Bring us your testing challenge — we’ll help you build a platform that keeps your components and your customers moving forward.
Schedule a Consultation and check out MCE’s Full Capabilities