Tag: reliability testing

It’s a familiar situation. A team goes into a certification test expecting a pass. Instead, they leave with a failure, a high unexpected cost, and a delayed launch. In most cases, the issue is not carelessness. It’s a misunderstanding of what product compliance testing really involves.

They treat certification as just another step.
In reality, it’s the point where everything is locked in.

 

What is pre compliance testing?

Pre compliance testing is the process of testing a product against regulatory requirements based on prototypes that are not yet representative of production units. It also involves a review of the design files, including the bill of materials.

It is often done in the same lab environment, with the same methods and equipment, and by the same technicians and engineers, as the tests done just before production. Sometimes it is done in a less formal way by the design team.

The goal is simple: find problems early, before they become expensive failures.

For electrical products, this often applies to:

• UL and CE (LVD) electrical safety testing
• FCC testing requirements (EMC and emissions)
• Reliability and environmental testing

You can learn what the regulations behind those tests are here: 11 Common Electronic Product Certification And Compliance Requirements

Prototyping vs final product

Early in development, your product is still flexible.

You can change the PCB layout. You can swap components. You can adjust mechanical design without major consequences.

This is your prototyping phase.

Later, things become much more rigid.

Tooling may already be built. Suppliers are aligned. Schedules are tight. Every change has a cost and a delay.

This is your final product phase.

Certification testing happens much closer to the second situation.

If you discover issues at that point, you are not just fixing a detail. You are potentially reopening the design.

If certification testing is your first serious validation, you are taking a risk.

If it’s your final confirmation, you are in control.

Why products fail FCC and compliance testing

Most failures come down to predictable issues.

Common examples include:

• Excessive emissions during EMC testing
• Poor grounding or shielding in PCB design
• Component choices that do not meet safety standards
• Weak sealing leading to failure in waterproof or IP testing
• Structural weaknesses revealed in drop or vibration tests

These are not random problems. There are design issues that could have been identified earlier with proper pre compliance testing.

Pre-scanning: catching issues before testing

In many cases, especially for electrical safety and EMC, testing starts before physical samples are even ready.

This is called pre-scanning.

At this stage, engineers review:

• PCB layout and architecture
• Critical components
• Grounding and shielding strategies
• Known risk areas against standards

This is closely related to a design for manufacturing (DFM) review, where potential production and compliance risks are identified early.

The earlier this happens in the new product introduction process, the more options you have to fix issues without major redesign.

Pre-testing for reliability and durability

The same approach applies beyond compliance.

Before certification, products should also go through:

• Product reliability testing
• Environmental testing (temperature, humidity)
• Drop and vibration testing
• Waterproof and ingress protection testing

These tests are part of a broader product validation testing strategy. You are not trying to “prove” the product works. Instead, you are trying to make it fail, early and cheaply.

How to run effective pre compliance testing

To get real value from pre-testing, follow these principles:

1. Replicate real test conditions
Work with labs or engineers who understand certification standards and can approximate them.

2. Test early, not just once
Run multiple iterations as the design evolves.

3. Focus on high-risk areas first
EMC, electrical safety, and mechanical durability are common failure points.

4. Learn from the lab
Whenever possible, observe how tests are performed. You will gain insights that reports alone cannot provide.

5. Work with labs that give feedback
The best partners do more than test. They help diagnose failures and suggest design improvements.

The goal: make certification predictable

By the time you reach official product certification testing, there should be no surprises.

You should already understand:

• How your product behaves under test conditions
• Where the risks were
• What changes were needed

At that point, certification becomes a formality. Not a gamble.

Final thought

If certification testing is the first time your product is pushed to its limits, you are taking a significant risk.

If it comes after structured pre-testing and pre-scanning in a validation process, you are simply confirming what you already know.

That shift is what separates delayed launches from predictable ones.

FAQs: Pre compliance testing

• What is pre compliance testing? Pre compliance testing is early-stage testing done before official certification to identify design issues and reduce the risk of failure.
• Why is pre compliance testing important? It helps avoid costly failures in certification tests, reduces redesign cycles, and shortens time to market.
• What is the difference between pre-testing and certification testing? Pre-testing is informal and used for learning and iteration. Certification testing is formal, controlled, and required for regulatory approval.
• When should pre compliance testing be done? As early as possible during product development, ideally starting with design reviews (pre-scanning) and continuing through prototype testing.
• Can pre compliance testing guarantee passing certification? No, but it significantly increases the likelihood of passing by removing major risks beforehand.

Editor’s note: Caleb Vainikka gave the analogy of a certified test being like a final exam over on LinkedIn, and I’ve dug into the topic deeper in this blog post.