Modern Melt Flow Indexing Advances Polymer & Plastics Testing | Tinius Olsen

Modern Melt Flow Indexing Advances Polymer & Plastics Testing

Jena Warren — Fri, 10 Apr 2026 16:41:12 +0000

Modern Melt Flow Indexing Advances Polymer & Plastics Testing

You Will Learn:

How digital advancements are shifting MFI testing
Which plastics and polymers benefit most from loadcell-based melt flow analysis
How deeper data insights improve new materials being developed for demanding applications

Evaluating the processing behavior of thermoplastic materials is becoming more intuitive, thanks to the use of automation and digitization in melt flow indexing. Materials testing in general is increasingly reliant on digital workflows, IoT-enabled instrumentation, and integrated robotics to enable more intelligent interpretations of material behavior.

Melt flow index (MFI) testing determines a polymer’s melt flow index value as well as critical parameters like material viscosities and batch-to-batch consistency. With the introduction of new loadcell-based melt flow indexers, materials testing environments across the board gain critical insights into polymer viscosity, molecular structure, and processing performance.

Overview

This white paper discusses how a material’s properties affect MFI as well as the reasons certain polymers are better suited for specific applications, as determined by the MFI. It also explores the differences and applications of traditional versus digital melt flow indexers and the application environment where each is best suited.

Digging deeper into the new digital advancements afforded by the loadcell-based MP1500, the paper examines individual application environments and how new analytical insights can contribute to better productivity, improved operations and the development of new polymer compositions.

Compliance to ASTM D1238 and ISO 1133 for MFIs is also reviewed along with the current landscape of the digital materials testing environment and the MFI’s role within.

Advanced Melt Flow Indexing Creates Better Work Environment; Easier Testing

Jena Warren — Tue, 03 Feb 2026 06:56:01 +0000

January 2026

Advanced Melt Flow Indexing Creates Better Work Environment; Easier Testing

As a cornerstone of quality control for polymers and plastics, melt flow indexers (MFIs) play a key role in understanding the processing behavior of these types of materials.

Traditional melt flow systems are grounded in the physical interaction between the machine and operator to set up and perform melt flow tests, from loading and unloading the deadweights to properly cleaning the equipment once a test is complete. Repeatability relies heavily on the consistency and stamina of the operator to replicate test conditions across multiple testing scenarios.

A deadweight system is still the mainstay of the industry, but as automation and digitization continue to permeate materials testing environments, loadcell-based technology is starting to gain influence across various melt flow testing applications throughout laboratories, research and development facilities and plastics manufacturers alike.

This advanced melt flow technology offers a clear, practical shift to better efficiency, accuracy, and operator safety in test environments, especially those with variable testing requirements, such materials with different viscosities or compositions as well as facilities with high testing frequencies and fluctuating loads. (Figure 1)

Considerations When Using Traditional MFIs

The manual nature of traditional melt flow indexers puts operator ergonomics at the forefront of workplace safety. Even with an automated deadweight loader, a person still needs to physically manipulate several steps of the load set up, such as making manual judgements and verifications. This can equate to operator strain and fatigue as well as increased risk of injury.

Repetitive, manual tasks are also a part of the traditional MFI testing process. One example is cleaning the system, which takes time and effort and must be done proficiently to ensure batch consistency and avoid cross contamination among different samples.

The industry is looking towards loadcell-based melt flow testing, not only for operator safety and production efficiency, but also to incorporate better data analysis and reporting, as the world of materials testing continues to become digitized. (Figure 2)

Loadcell-based Melt Flow Testing For Improved Production

Digital melt flow indexing becomes even more significant as material compositions change, due to new additives and fillers being incorporated into today’s polymers and plastics in addition to the plastics industry’s move towards sustainability. Commonly referred to as the circular economy, plastics sustainability focuses on materials that are reused, recycled and kept in circulation for as long as possible.

The melt flow index helps determine material performance and quality in a given application. Determining how variations in the MFI correlate to material properties, like density and mechanical behavior, means you have a deeper understanding of how the MFI value affects the material being tested. (Figure 3)

Ensuring new variations and recycled or reused plastics still adhere to the required standards outlined by ASTM D1238-23a and ISO 1133-1:2022, for example, ensures accurate and repeatable results. These standards provide a reliable benchmark that drives quality, enables material selection and supports advancements in material science.

As ASTM points out, “The flow rate obtained with the extrusion plastometer [melt flow indexer] is…an empirically defined parameter critically influenced by the physical properties and molecular structure of the polymer and the conditions of measurement.”

But beyond its uses in materials evaluation, a digital melt flow tester can improve operator safety and production efficiency, giving those on the floor a better work environment as well as insights into evaluating test results. It also empowers them to make real-time changes as needed and perform a different set of process and procedural tasks that can improve overall quality and production efficiency.

When Does A Digital MFI Make Sense

As materials testing becomes more digitized, integration across testing systems and platforms will continue to increase. The timing of adding a loadcell-based MFI to your current test set up comes down to assessing its integration from a holistic viewpoint, so ask yourself these questions:

What are the current digital capabilities of my materials testing system?
Is there a timeline for bringing my whole system into a digital environment?
Am I handling several different polymer types that require many load variations?
Will this help meet ASTM & ISO requirements for new materials development?
Am I happy with the accuracy and repeatability of my current MFI?
Could a digital MFI improve my time between tests?
Do I need to better integrate my MFI results into my overall reporting and analysis?
What will these improvements do for overall efficiency and analysis?
What opportunities will this open for my operators?

What’s Next for Melt Flow Testing

The move to a digitally-enhanced MFI allows those involved with materials testing the ability to focus less on the mechanics of testing and more on the quality of results. The added benefits of operator efficiency and a safer working environment only enhance the implementation of a loadcell-based MFI within a testing environment.

This is especially useful in applications where multiple loads are being manipulated on a regular schedule as well as in environments where new additives and composites need evaluation, so testing personnel can take a more active role in evaluation and analysis to ensure quality results in today’s plastics and polymer melt flow testing.

Ways to Use Exported Data for Better QA Manufacturing

Jena Warren — Tue, 16 Dec 2025 16:24:06 +0000

Ways to Use Exported Data for Better QA Manufacturing

Data has become extremely important in manufacturing. It serves as a collection of information and statistics used for reference or analysis. When gathered from a variety of sources along the production environment, this data gives manufacturers valuable insights to help optimize the supply chain, reduce costs, and improve the quality of their products.

Data analytics takes this a step forward, helping manufacturers predict maintenance needs, prevent downtime, and create a safer work environment. By effectively using data in manufacturing, businesses become more sustainable and more profitable. (Figure 1)

Automation for Improved Testing Efficiency

By running tests continuously or in parallel, often 24/7, automated materials testing is far more reliable than manual testing. It improves testing efficiency by ensuring consistent, repeatable test parameters and reducing errors. The larger datasets generated by an automated materials testing system provide better, more reliable insights, while offering traceability and reproducibility. (Figure 2)

In its Digital Maturity Index 2023, Deloitte “found that 98% of 800 surveyed manufacturers in four major global economic regions have started their digital transformation journey, compared with 78% in 2019, and respondents reported cost optimization, operational efficiency, product innovation, and improving customer experience as key drivers for the shift.”

But how do these systems collecting and exporting data provide better quality assurance manufacturing? And how has the availability of that data improved manufacturing environments?

Data Access Made Easy

As the digital infrastructure continues to grow, working with the data gathered during test, whether for the demanding rigors of R&D or the charting and analysis functions of QC testing, is critical to modern materials testing. Horizon software from Tinius Olsen, for example, offers an intuitive interface, providing quick access to a number of usability and access points, such as:

Test method library
Test editor
Tabbed test and recall area
Multiple machine control
Output editor
Method editor
Result editor
Multifaceted security
Data importing
Report consolidation
Webcam functionality

This ease of gathering and analyzing data improves the manufacturing environment by enabling the collection, processing and analysis of statistically meaningful information that can help direct quality control and production efficiency.

The advanced, data-centric environment provided by the Horizon software delivers a powerful, adaptable interface that supports both research-intensive development and standardized quality assurance work to meet the evolving needs of materials testing. The platform can be used integrated into virtually any materials testing environment.

Putting Unprecedented Data Insights into Action

A typical data collection program will offer a variety of different graphs that can be produced per test, once all data has been gathered. But today’s data collecting and analysis methods can go much, much further relying on data across the continuum, from live data on a currently uploaded specimen to historical data obtained through several previous test iterations. (Figure 3)

In addition to accessing live data during testing, acceptable limits of the results can be selected as well. The results can be viewed graphically in multiple formats and customized for user-specific reporting. Unique results can be calculated from parameters and from other tests and equipment. Information can be exported to a variety of different formats, making data gathering and reporting seamless.

Following International Test Standards

If your testing regimen follows a quality control analysis to a variety of international standards, make sure you enlist a software program with a test method library that has been written in accordance with different international test standards, including ASTM, ISO, EN, BS DIN and more.

It should also allow for customized test setup, using a standard as a template, and be offered in multiple languages and dialects as well as with an option for users to create test method, giving them complete control over how the test machine performs throughout the course of the test. This will also help give you a wide variety of data to match your materials testing needs.

For example, the Horizon platform can convert hardness values into five different hardness (and tensile) scales simultaneously according to international standards (ISO/ASTM). For a global company where materials are tested at various locations, each follows different testing standards. If the same material is to be used across all sites, but the required validation varies according to local standards, different hardness scales may be needed.

For instance, the QA facility might follow ASTM standards requiring Rockwell hardness, while another location adhering to BS standards may specify Brinell hardness for the same material. In such cases, repeating the test in every scale is redundant — instead, the material can be tested once and the results converted using conversion function in Horizon, allowing the report to include equivalent hardness values across all relevant standards.

Conclusion: How is Data Used in Manufacturing?

The innovative use of data in manufacturing appears to be a stabilizing force for the global manufacturing industry. Data helps to predict future outcomes using both current analytics and historical data. This advanced methodology helps to decode complex manufacturing processes and improve materials testing outcomes.

Collecting data on the quality of a specific part can be helpful for auditing production processes and ensuring that work is standardized, as well as helping to reduce waste.

Materials testing analytics improve product quality by capturing machine-level information, boosting production yield and throughput. Data that shows the cost and effort involved in developing products helps quickly identify problems and predict issues. This aids in quality production, while significantly reducing costs. The use of data in manufacturing environments, especially in materials testing, has become a pinnacle of operational improvement.

For a deeper dive into using data in your materials testing environment, check out our white paper on Integrated Data Analysis Improves Efficiency in Materials Testing

Recent Shifts in Melt Flow Indexing

Jena Warren — Mon, 08 Dec 2025 14:32:12 +0000

Recent Shifts in Melt Flow Indexing

Over the past several years throughout the automotive, packaging, healthcare and electronics industries, the demand for plastics and polymers has been on the rise, increasing the frequency and use of melt flow testing across most manufacturing environments. Each industry must follow stringent quality control guidelines, as put forth by ASTM and ISO, to gauge precise measurements of melt flow properties, maintain quality control and establish consistent product development processes. (Figure 1)

Melt flow testing’s critical role helps determine the flow properties and viscosity of plastics and polymers in a variety of production applications. Melt flow index (MFI) testers are one of the staple materials testing systems companies use to meet the widely accepted ASTM 1238 D-23a and ISO 1133-1:2022 standards as well as comply with specific industry regulations.

Melt Flow Testing Basics

Manufacturing processes have different requirements based on the production method being used, the material being processed and the intended final product, but the melt flow test process is basically the same:

Test Preparation: a known quantity of polymer granules is added to machine’s barrel
Polymer Melting: polymer is heated to a specific, consistent temperature
Load Applied: Force is applied to the piston (physical weights or via load cell)
Polymer Extruded: Molten polymer is pushed through a die
Extrusion Measurement: extruded polymer is collected over a specified period
MFI Calculation: value is determined based on the extruded polymer weight and timeframe

The standard units to express the MFI calculation – typically g/10 min for melt flow index MFR or cm³/10min for volume flow index MVR (ASTM/ISO) – remain the same, allowing for consistency and comparability across different materials and testing conditions.

What MFI Testing Systems are Available?

Traditional melt flow indexers employ a set of physical dead weights that are either manually or automatically placed on the machine for testing. This type of system is best suited for applications with a stable environment, where load, temperature, and material composition don’t change.

However, most manufacturing facilities as well as research labs, universities and third-party testing companies need to accommodate at least some variables in the melt flow testing process.

Load cell-based MFI systems are key in today’s materials testing environments to enable quick and easy modifications to test set ups. These systems also deliver far more precision, control, measurement, and available data for streamlined calibration as well as improved testing efficiency and operator safety across the MFI test process. (Figure 2)

A closed loop system, like the MP1500 Loadcell Melt Flow Indexer, will detect small variations in flow that a conventional weighted system may miss and can measure the sensitivity of force across the entire test for higher accuracy in the results. It works with closed loop, where load is applied by a motor and ball screw system with a PID (proportional integral derivative) control feedback. With no dead weights, human error is reduced and results across different labs and operators are more repeatable and consistent.

Integrated sensors enable real-time tracking of melt viscosity and flow behavior during extrusion as well as continuous monitoring of piston position, load, and displacement, and even rapid data logging and analysis.

Operators can configure machine options and program user settings (language, units, alarms, etc.) from an integrated display interface as well as set and store individual test protocols for rapid recall. The unit can be controlled via the touchscreen when combined with a comprehensive software suite, like Horizon, the equipment becomes a test system powerhouse, improving overall manufacturing operations through shared data and advanced analytic capabilities. (Figure 3)

Emerging Markets and Industry Needs

Load-cell based melt flow test systems are gaining popularity across a wide range of industries, from manufacturing, compounding, and packaging to automotive, medical, 3D printing, and recycling. By providing greater accuracy, automation, flexibility, and efficiency, these systems are instrumental in modern quality control labs and R&D environments as well as where precise material control and consistency is required.

As the use of plastics in these industries continues to evolve, there will be a steady growth in the need for melt flow testing. Technological advancements and efficient processes will be paramount in ensuring new applications and production environments maintain the level of quality performance demanded of today’s plastics and polymer resins and powders.

How Melt Flow Can Improve Plastics Production Efficiency

Jena Warren — Thu, 04 Dec 2025 15:06:33 +0000

How Melt Flow Can Improve Plastics Production Efficiency

Melt flow testing is arguably one of the most useful tests in the plastics and polymer industry. It primarily helps measure the melt flow rate (MFR) of thermoplastic materials by determining the ease with which plastics and polymers can be melted and processed under specified conditions. Understanding how a material behaves during processing and manufacturing provides valuable insights into how it will respond in practical applications. (Figure 1)

There are several ways that the melt flow index (MFI) contributes to the production and manufacture of plastics and polymer-based products, including:

Evaluating quality and consistency
Improving production efficiency
Meeting regulatory requirements
Enhancing customer satisfaction

Why is Material Behavior Important

MFR indicates how easily the polymer or plastic flows when melted. The flow depends on the material’s viscosity—think of viscosity as resistance. The thicker a material, the higher the viscosity and the slower it will flow, resulting in a lower MFI. Similarly, a plastic composition that flows easily has a higher MFI and a lower viscosity.

The length of the molecular chain of the resin, called molecular weight, is also related to flow. Shorter polymer chains with simple geometry and thinner consistency offer less flow resistance. Fiber spinning, film blowing and thin-walled injection molding are typical production methods for this type of material.

Longer chains with a high molecular weight and more complex structure will have greater resistance as well as a thicker consistency. This material is used for blow molding, extrusion, and thick-walled injection molding, for example.

A melt flow index tester is the most popular device in the plastic industry to determine a polymer’s MFI value. It measures material viscosities and enables validation for batch-to-batch flow consistency that helps prevent defects in processing and ensures a reliable final product.

Understanding MFI is a notable aspect in plastics production, since some applications, such as thin film, precision parts and fiber and filaments, require a polymer with a higher MFI, so it flows easier. Other applications requiring more durable parts that withstand warping or shrinkage, for example, need a lower MFI polymer, so the final product will maintain its strength. These include containers, pipes, industrial housings, and automotive parts.

When choosing materials for a specific product or switching between suppliers, knowing the MFI provides a standardized way to compare different plastics or grades of the same polymer. Product quality remains consistent throughout the manufacturing process.

Plastics During Processing

During melt flow testing, a constant load is applied to a standardized sample of material, while measuring the rate of protrusion through a specific opening to get the MFR.

For test environments where load, viscosity, composition, and temperatures are constantly changing, such as research labs, universities or third-party testing facilities, an MFI with a load cell is a practical choice. These digital-based systems enable push-button calibration and load setting to quickly move from one test set up to the next, accounting for all the application variables.

Traditional machines using a manual or automatic dead weight loading system are sufficient when testing the same mixture consistently under the same load, as found throughout manufacturing, but production efficiency and plant modernization may still warrant a load cell test system in many of today’s manufacturing environments. (Figure 2)

Consistent Quality Through Industry Standards

The melt flow rate helps to define the needed parameters, such as temperature, pressure, and screw speed, for a material during each specific manufacturing process.

Without this insight into how that material may react during manufacture, the polymer may be processed incorrectly, leading to quality or safety concerns, such as poor surface finish, voids, or incomplete filling of molds.

ASTM D1238 and ISO1133, the most common industry standards for melt flow testing, are also an integral part of melt flow indexing, as they further ensure the quality and consistency across different manufacturing environments and polymer applications.

ASTM notes that ASTM 1238D-23a is a “standard test method for melt flow rates of thermoplastics by extrusion plastometer.”
Per ISO, ISO1133-1:2022 is for the “determination of the melt mass-flow rate (MFR) and melt volume-flow rate (MVR) of thermoplastics.”

Each provides testing parameters for a manual method – (Procedure A; Method A) as well as for an automatic timed flow measurement (Procedure B; Method B).

Impact of Material Quality on Manufacturing

With global shifts in the overall supply chain, from raw material to final products, manufacturers need reliable methods to evaluate production at every stage of product development. Having a good understanding of the manufacturing process and identifying any possible defects that could appear in the final product is on the forefront of the minds of plant engineers, product developers, and CEOs, alike. (Figure 3)

Physical properties of raw materials, especially, are under scrutiny to ensure that the correct material or material formulation is selected for the right application, and that the material being used is suitable for the end product. Melt flow testing is one such test that helps companies ensure the plastics and polymers being used are consistent in quality and are appropriate for the intended end use.

Check out our Melt Flow Index Testing playlist on YouTube to learn more.

Building Trust Through Innovation in Materials Testing: LTI and Tinius Olsen’s Collaborative Journey

Jena Warren — Wed, 11 Jun 2025 04:53:05 +0000

Building Trust Through Innovation in Materials Testing: LTI and Tinius Olsen’s Collaborative Journey

Introduction

In the world of materials testing, precision and reliability are paramount. Companies in high-stakes industries such as aerospace, nuclear, and additive manufacturing depend on advanced technology to meet rigorous standards.

Based outside of Philadelphia, PA, Laboratory Testing Inc. (LTI) has been at the forefront of materials testing for over 40 years, ensuring that its clients receive the highest level of accuracy and efficiency. Its long-standing relationship with Tinius Olsen has played a crucial role in fostering innovation, streamlining testing processes, and enhancing overall efficiency.

A Relationship Built on Collaboration

LTI’s partnership with Tinius Olsen is more than just a customer-supplier relationship — it is a dynamic collaboration. Over the years, LTI has provided valuable feedback to Tinius Olsen, influencing the development of new and improved testing systems.

As Mechanical Testing Manager Paul Szczepaniak from LTI shares, “Being part of the actual product development is an interesting experience. There’s a good back and forth between the companies, because we see what we need, and Tinius Olsen is always willing to accommodate.” (Figure 1)

This direct engagement has resulted in tailored materials testing solutions that address real-world challenges, allowing LTI to optimize its operations, while contributing to the continuous evolution of Tinius Olsen’s technology.

Supporting Industries Through Innovative Solutions

To maintain an industry leadership position in the diverse range of industries it serves, LTI relies on sophisticated test systems that seamlessly integrate into its workflows. Tinius Olsen’s Horizon test system has been a game-changer for LTI, providing a streamlined and customizable platform that enhances data acquisition and usability.

“The ability to use that system and have it constantly updated has been invaluable,” says LTI’s Mechanical Testing Coordinator, Nathan Moyer. “Even if we request a specific feature, unless it’s an extremely complex demand, they generally implement it within a day or two.” This level of responsiveness and agility sets Tinius Olsen apart from its competitors, ensuring that partners like LTI can maintain its competitive edge.

Efficiency and Innovation with Non-Contact Extensometry

In high-volume materials testing environments, efficiency is key. LTI has significantly enhanced its operations with Tinius Olsen’s Vector Extensometer, which eliminates the limitations of traditional contact extensometers. The digital extensometer integrates adaptive AI capabilities with optical hardware to reduce test throughput times and complexity, automating the process of capturing strain and improving measurement accuracy, data consistency and operator safety. (Figure 2)

“Since it is non-contact, we could continuously run sample after sample and never have to re-verify the calibration of the extensometer,” Nathan explains. “And because it gives us digital, data-driven materials test processing, we have access to synchronized data in real-time, with virtually no lag.”

These advancements have minimized downtime, reduced costs, and improved throughput. The combination of Tinius Olsen’s precision hardware and sophisticated software has enabled LTI to optimize its testing processes like never before.

Reliability: The Backbone of Testing Operations

In a fast-paced and demanding industry, equipment reliability is non-negotiable. At LTI, almost every mechanical testing process involves a Tinius Olsen test system, from universal testing systems (UTMs) and hardness testers to impact test systems and melt flow indexers. Tinius Olsen systems form the backbone of LTI’s daily operations. This level of reliability ensures that LTI can meet the high standards required by its clients, while maintaining operational efficiency.

Driving Industry Innovation Together

Beyond advanced and innovative system offerings, Tinius Olsen’s active participation in ASTM standardization efforts further underscores its commitment to industry advancement. Paul shares, “If I receive a request from a customer that falls outside normal scopes, I can reach out to them and say, ‘Here’s what I’m trying to do. What can we do?’” This open collaboration has led to the development of custom instruments and unique testing setups that cater to LTI’s specific needs.

Moreover, Tinius Olsen’s commitment to swift customer support ensures that LTI experiences minimal downtime. “We just had a long-standing system go down, and Tinius Olsen had us back up in three days, whereas with another company, it could have taken weeks,” Paul highlights.

Conclusion

LTI’s decades-long relationship with Tinius Olsen exemplifies what true collaboration in materials testing looks like. Through constant innovation, responsive customer support, and advanced technology, Tinius Olsen has not only helped LTI optimize its processes, but has also played a pivotal role in advancing the materials testing industry as a whole.

For companies looking for a trusted partner in materials testing, the success story of LTI and Tinius Olsen speaks volumes. When precision, efficiency, and reliability matter most, Tinius Olsen delivers solutions that stand the test of time.

Hear it direct. Check out this video from Nathan and Paul at LTI about their experience working with Tinius Olsen.

Challenge the Naysayers in Engineering Design

Jena Warren — Mon, 02 Jun 2025 00:10:22 +0000

Challenge the Naysayers in Engineering Design

The engineering design field has witnessed a multitude of profound changes and emerging trends in the past decade with digital transformation in full swing. As companies harness available technologies and leverage design innovation and products to enhance business capabilities and customers’ experience, engineers are facing new and complex challenges to adapt processes and ensure product reliability.

This rapid growth of technology is reshaping the way engineers design and develop equipment as they look further into the future to ensure compliance for quality testing of products to meet both existing and evolving standards.

Thanks to this, the role of engineering redesign and quality testing has become more crucial than ever. And while some may think these new challenges merely pose stumbling blocks, we see them as ways to improve the role of materials testing across all applicable industries.

Maintain Design Integrity

Engineers are confronting more instances of solving design problems due to the rapid speed at which technology is advancing. For materials testing, this presents some unique challenges, as engineers also must meet specific industry standards for safety, quality and production requirements. There is a careful balance between the innovation happening within their production environments and the need to adhere to existing industry standards.

Lexi Patania, mechanical design engineer for Tinius Olsen, noted, “Some may believe that, with new technologies comes new machinery, and that is true to an extent. But many aspects of the development and testing process can be redesigned and adapted to meet new technical challenges.”

She goes on to explain, “There are often scenarios, where the dimensions of a specimen, or it’s expected force, may fall outside the range our normal test fixture accepts. That involves adapting the current fixture to meet the required dimensions and load capacity, as well as any other design constraints. We do a lot of that, but we’re also very involved with developing new designs to meet the growing complexities we see in our customers’ applications, while maintaining much of the existing test infrastructure.”

New Challenges Mean Opportunities

Patania explained a recent project for hardness testing, which typically uses a flat or v-anvil fixture when testing typical Rockwell specimens.

This particular application, though, involved a specimen with complex geometry and several different testing locations along its length and rotational axis, all of which needed support, directly through each of the test points. Because each test point had different geometric attributes, and the sample must be fixed when load is applied, the fixture needed to be adaptable in one linear and one rotational motion, and lock in place at all 16 positions.

She continued, “We were able to develop a fixture that tests 4 points, turns once to accommodate testing of the other 4 points, and is interchangeable with a similar fixture to obtain the remaining 8. This design requires minimal operator effort, pinpoints exact test locations, and provides the results needed across the entire specimen in a way that had not been done before. It’s exciting to solve these challenges for our customers.” Identifying and solving testing problems according to set industry standards is a large part of the innovation at Tinus Olsen. (Figure 1)

Consistency Ensures Reliability in Innovation

Standards are essential to fueling innovation as well as maintaining a level of confidence in products. The integrity of broad-based frameworks establishes accurate and workable principles for technology adoption and interoperability. The research and development (R&D) stage, especially, plays a key role in meeting the constant innovation of engineering as well as adjusting standards to meet changes.

As ASTM notes, testing standards provide guides for the proper procedures employed in the determination of the physical, mechanical and metallographic properties of certain materials…to allow metallurgical laboratories, manufacturers, and other producers…to examine and evaluate such materials for strength and quality to ensure safety towards their end-use.

Adopting Reengineered Solutions

The critical role that standards from organizations like ISO and ASTM play in the materials testing industry is undisputed. For decades, these standards have served as our barometer of product quality and customer assurance. Our next step as an industry is to facilitate the alignment of the standards with the engineering redesigns being developed that are solving the new challenges we are seeing in manufacturing and product testing. (Figure 2)

Engineering redesign has become more prevalent in the past few years as supply chain issues have grown more prominent. By practicing engineering redesign tactics, the industry can keep up with growing technologies, while still providing quality products to consumers. Have an engineering challenge you want us to take on? Check out our Service & Support page for your local contact.

New Extensometer Technology Facilitates Better Materials Testing

Jena Warren — Wed, 30 Apr 2025 20:13:01 +0000

New Extensometer Technology Facilitates Better Materials Testing

With tight timelines and even tighter budgets, the pressure to deliver high-caliber products has never been more important. In a world where quality and reliability can make or break a company’s reputation, cost-effective testing techniques that improve testing efficiency and benefit from modern technological advancements are the ones that will give R&D, engineers and test facilities a distinct advantage.

Since the standardization of extensometry in the 1950s, the use of an extensometer—a sophisticated ruler used to measure displacement or strain on the surface of a test piece—has not changed significantly. However, it has become evident that this testing methodology needed a boost to keep pace with modern applications, where other computing mechanisms have been built into materials testing systems.

Increased Test Efficiency

The introduction of new optical extensometer technology has made traditional, mechanical tools nearly obsolete. It uses intelligent non-contact, high-accuracy measurement techniques to eliminate the common challenges of traditional contacting and non-contact extensometers, while also offering some distinct advantages.

For those looking to take an easy, first step toward automating their existing materials testing process in order to maintain consistency in test performance, the new Vector Extensometer (Figure 1) reduces operator involvement, decreasing manual errors in calculation or calibration as well as simultaneously measure longitudinal and transverse strain.

This self-contained, plug-in-and-power-up precision system eliminates all the tricky and cumbersome set-up options associated with other optical extensometers and removes the need for multiple PCs and interface equipment.

Using adaptive Artificial Intelligence (AI) coupled with optical hardware, Vector reduces testing time and is ideal for complex environments, such as assessing extremely fragile specimens as well as small and non-uniform specimens, measuring strain through failure or operating in harsh or dimly lit applications.

Tackling Common Trouble Spots

For each trouble area that extensometry has encountered in the past, now there’s an easy solution.

Poor grip on a specimen? Vector is non-contact. Worn edges? No problem, Vector is laser-enabled. Improper length? It is compliant with ASTM E83. The need for manual calculation? Measurements are now computerized. Worried about accuracy and the possibility of improper data collection? AI-based capture eliminates that risk.

Vector addresses it all, clip sensitivity, dulled edges, physical marking, manual calibration fluctuation, non-uniform specimens, synchronized force and strain data. It delivers quality results in every test. (Figure 2)

Adoption and Usability

Setup is straightforward, so adding it to existing equipment is simple. And what is even better, there are no special skills required to run it. Everyone from new hires to company veterans can set up the machine and start running tests in no time.

Vector reduces risk because it is very hands off and streamlined, with processing power contained within the unit itself. Users don’t need a separate PC to process and manage the data. The system pre-processes it and sends direct to the main PC.

This cutting-edge technology is the very latest in digital extensometry, enabling synchronized force and strain data in real-time, with no lag.

Optimal ROI

This step-change in digital, data-driven materials test processing is seen across a wide range of industry sectors, with Vector meeting or exceeding ISO 9513 Class 0.5 and ASTM E83 Class B1 standards. Vector provides optimal overall ROI, thanks to its streamlined testing process, accurate results in every test scenario and the elimination of consumable parts that need replacement.

Accuracy, resolution, data rates, control, precise adherence to test standards, calibration, measurement of uncertainty and traceability – this new advancement in extensometry can handle them all.

To learn more about available Vector models and how new optical extensometer technology facilitates better materials testing, download our whitepaper Modern Extensometry for a Data-driven World.

Integrated Data Analysis Improves Efficiency in Materials Testing

Jena Warren — Mon, 17 Mar 2025 17:52:38 +0000

Integrated Data Analysis Improves Efficiency in Materials Testing

You Will Learn How To:

Make data more actionable and accessible
Speed up testing and reporting capabilities
Ensure adherence to the latest industry standards
Facilitate better operational efficiencies

By creating a holistic approach to material testing, intuitive software platforms are cohesively managing the complex data sets generated by today’s material testing equipment. Instead of siloed environments, comprehensive software suites are driving business value and operational efficiencies through greater visibility within test results.

A testing infrastructure that uses a modern software platform provides enhanced data analysis to enable critical insights, such as statistical analysis, trend identification and predictive modeling, as well as help improve how material properties and behavior are evaluated.

Overview

This white paper reviews how Tinius Olsen’s user-friendly, universal Horizon material testing software platform improves overall manufacturing operations through shared data principles and advanced analytic capabilities. It also outlines the benefits of simplified reporting and an easy user interface to provide improved testing analysis and actionable intelligence.

Automotive OEMs Improve Materials Testing ROI With In-house Infrastructure

Jena Warren — Wed, 30 Oct 2024 20:49:14 +0000

Automotive OEMs Improve Materials Testing ROI With In-house Infrastructure

Materials testing is an integral part of the automotive industry. It provides quality assurance by ensuring that vehicles, including all their components, are safe and reliable, while also meeting the regulatory standards required by the federal government. Although third-party testing centers are a popular choice among OEM suppliers, implementing an in-house materials testing system can quickly provide a better, and more significant, return on investment.

Recent Effects of Recalls and Safety Concerns

While maintaining profitability is a key area for the stability of any business, in automotive component manufacturing, trust among the consumer and the automakers themselves is worth more than its weight in gold. Recent years have seen an increase in high profile instances of recalls, defects and unsafe operating environments that have eroded consumer confidence, putting more emphasis on the value of a company’s reputation and ability to provide reliable, safe automotive systems. (Figure 1)

Sending parts out for third-party inspection and verification is one method of quality control, but more OEM suppliers are evaluating the benefits of an in-house materials testing system that affords them the opportunity to better manage yield and inventory, with speedy responses to production defects and better oversight of the actual production process.

Improving ROI and Consumer Confidence

Investing in an in-house materials testing system empowers OEMs to improve product quality, innovate effectively and maintain competitiveness in an industry that is not only extremely demanding, but also regulated by standards, including ISO, ASTM and ES. While the initial investment may seem higher than a weekly shipment to an off-site testing facility, the long-term savings can be substantial, with a return on investment seen quicker than one might think:

Reduction in Testing Costs: OEMs avoid immediate recurring costs, like testing fees, associated with hiring third-party testing services. Over time, in-house testing equipment reduces the cost and time associated with sending parts out for testing.
Faster Time-to-Market: An in-house infrastructure allows for rapid testing and prototyping, in turn creating faster product development cycles. OEMs can respond more rapidly to design changes or new requirements, reducing delays in the production process. Turn-around times are faster, too, since materials can be tested as needed.
Custom Testing Capabilities: Developing testing methods that specifically address unique materials and performance needs, like harness, metal and corrosion testing, means OEMs also have the ability to experiment with new materials and technologies that could lead to new and more innovative products. Continuous improvement is possible when testing in-house because it allows OEMs to focus on specific materials and processes, refining testing strategies over time while working to enhance product development and innovation.
Data Ownership: With better control over testing data, the analysis and integration OEMs can implement into the development process helps to improve product quality and performance. Software-based management tools, like Tinius Olsen’s Horizon platform, provides computer-assisted data acquisition and machine control that collects, analyzes, graphs and stores data. It can also provide control over testing operations. (Figure 2)

A Streamlined Process: In-house testing encourages collaboration between a variety of different departments, including testing, engineering, and production, to create a more efficient workflow as well as help avoid delays and scheduling conflicts that often happen when using an outside testing facility.
Quality Control: Maintaining consistency and direct oversight of the testing process and protocols ensure that testing standards are adhered to, an important factor in the automotive industry. This leads to higher quality materials and components with fewer defects and recalls, which significantly impacts profitability. It also can lead to longer-lasting components and parts, which improves a brand’s reputation and customer satisfaction, translating into increased sales.
Ease in Scalability: Today’s materials testing systems are designed to scale with the needs of an OEM quickly and efficiently. This allows manufacturers to accommodate increased testing and production demands without a significant increase in cost. Some systems even perform multiple test scenarios within the same compact system footprint.

Before you look to invest in an in-house testing system, take stock of your most critical testing parameters. Equipment, like the Tinius Olsen universal testing machines, are designed to perform quality control tests on raw materials, like metals, polymers, textiles, rubbers and adhesives. A horizontal tensile testing machine tests for tensile strength, along with elastic modulus and corrosion resistance, in materials like alloys, composites and plastics and an indentation hardness materials testing machine can quickly and accurately determine the hardness value of metals, components, large parts and small precision parts used in cars. (Figure 3)

While the upfront costs of purchasing materials testing machines can seem overwhelming, the benefits and long-term advantages, including greater quality control, speed, flexibility, customization and security, align closely with an OEM’s goals of quality, efficiency and innovation. This can lead to a more favorable ROI in the long run and helps maintain a competitive advantage in this demanding industry.