Product development and production introduce different reliability concerns. A design may contain limited operating margins, while manufacturing can introduce defects into an otherwise capable product.
The Applied Technical Services Family of Companies (ATS FoC) provides HALT / HASS reliability testing to address these concerns at different stages. Highly accelerated life testing investigates design weaknesses. Highly accelerated stress screening evaluates production units for defects using a product-specific screening profile. Together, these methods can support a coordinated approach to environmental stress testing. Their effectiveness depends on how manufacturers investigate findings and implement corrective actions.
How Do HALT and HASS Support Different Product Stages?
HALT typically takes place during development. Increasing temperature and vibration stresses help reveal weak points and establish the tested design’s limits. Engineering teams can use these findings to assess changes before production. After modifications, further evaluation helps determine whether the identified weakness has been addressed.
HASS follows a different objective. It applies a defined screen to production hardware, seeking defects associated with components, assembly, or manufacturing variation. The distinction guides the program:
- HALT: Discover weaknesses and inform design improvements.
- HASS development: Establish and evaluate a suitable production screen.
- Production screening: Apply the approved profile and investigate detected problems.
A HASS profile should reflect the current design. Copying another product’s settings can produce misleading results or unnecessary damage.
What Environmental Stresses Can a Program Include?
Our HALT / HASS capabilities include thermal step stress, rapid thermal cycling, multi-axis vibration, and combined environments. We select the approach around the test article and agreed objectives. During HALT, stress levels increase to investigate product limitations. During HASS, a defined profile applies controlled exposure appropriate to screening.
Temperature changes and vibration can interact. Combined exposure may reveal behavior that does not appear when either stress acts alone. Monitoring must also match the product. Power status alone may not reveal a performance problem. Depending on the project, functional checks may need to examine outputs, communications, or operating sequences.
Which Manufacturers Benefit from HALT / HASS Reliability Testing?
These methods can support organizations developing electronics and electromechanical products with demanding reliability expectations. Typical users include aerospace suppliers, automotive manufacturers, medical device companies, and electronics producers. Contract manufacturers may also participate when screening forms part of a customer’s production requirements. A combined program helps teams looking to:
- Investigate weaknesses before production
- Evaluate changes to an established design
- Develop screening for manufacturing defects
- Examine concerns following supplier or process changes
- Connect laboratory findings with corrective action
The appropriate scope depends on the product’s maturity and available test history. Some projects require development work before production screening becomes appropriate.
How Does ATS Help Connect Test Findings with Decisions?
We begin by reviewing the product configuration, existing HALT data, functional requirements, and intended outcome. This discussion helps define responsibilities and reporting needs.
Our team documents test conditions and observed failures within the agreed scope. Clients can then use those findings to prioritize investigations and evaluate corrective actions. Neither method guarantees failure-free operation or establishes regulatory compliance by itself. Qualification, safety evaluation, and other required testing remain separate considerations. ATS performs HALT / HASS reliability testing in our ISO/IEC 17025:2017-accredited, ISO 9001:2015-registered testing laboratories.
Contact Us
Submit a request form on this page or contact us by phone at +1 (888) 287-5227 to discuss how HALT / HASS reliability testing can fit your development and production plans.
