Expert HALT & HASS Testing Services

HALT stands for Highly Accelerated Life Testing, a development method used to expose design weaknesses by applying increasing levels of thermal, vibration, and other stresses. HASS stands for Highly Accelerated Stress Screening, which is typically used in production to screen for workmanship or process-related defects after the product design has been stabilized.

HALT testing often takes several days to a few weeks depending on product complexity, fixture needs, instrumentation, stress profiles, and the number of failure-and-correction cycles required. Simpler evaluations may move quickly once samples and requirements are ready, while complex assemblies may require additional setup, monitoring, analysis, and engineering review between test phases.

HALT is primarily a design validation and weakness discovery tool used during development, while HASS is a production screening method used after design limits are understood. HALT pushes products beyond normal operating conditions to identify margins. HASS applies controlled stress screens to detect latent defects without consuming excessive product life.

Products with electronics, mechanical assemblies, controls, sensors, power components, medical devices, professional tools, vehicle systems, and industrial equipment can benefit from HALT or HASS programs. The best candidates are products where field reliability, warranty exposure, customer satisfaction, safety, or launch confidence are critical to business performance.

Common stresses include temperature extremes, rapid thermal transitions, random vibration, mechanical shock, combined stress conditions, and functional monitoring during exposure. The exact profile depends on product construction, operating environment, failure history, and screening goals. B83 can also support related environmental, vibration, shock, and data acquisition work under one testing program.

A typical project may require functional samples, product specifications, operating limits, power and signal requirements, performance criteria, known failure modes, applicable standards, and any preferred monitoring points. Clear documentation helps the laboratory design safe fixturing, define stress increments, capture useful data, and distinguish meaningful failures from setup-related issues.

HALT can damage or destroy samples because it intentionally explores operating and destruct limits. That is part of its value during development. HASS, by contrast, is designed to remain within established screening limits so production units are stressed enough to reveal defects without causing unnecessary life consumption or good-product damage.

B83 Testing & Engineering provides actionable test data, observations, and engineering insight to support quality decisions. Reporting may include test setup details, stress levels, functional responses, failure observations, data acquisition results, photographs, and conclusions tied to the agreed test plan. Documentation supports design improvement, validation, risk reduction, and production readiness decisions.