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Design Validation & Process Qualification

We validate performance, compliance, reliability, and manufacturability at every gate from EVT through DVT, PVT, and final PPAP submission.


At MarSum Solutions, validation and qualification are embedded in the design lifecycle. Prototypes are proven in the lab, verified against field stresses, and readied for volume production. Our plans align with safety, environmental, mechanical, thermal, electrical, and regulatory requirements, and they evolve through EVT, DVT, PVT, and (when required) PPAP Level 3/4 packages.

Design Validation Framework

We tailor coverage to program complexity, using a gated approach.

Engineering Verification Test (EVT)

  • Early hardware bring‑up and functional coverage
  • Initial thermal profiling and signal‑integrity checks
  • Simulation‑to‑bench correlation (control stability, power throughput, EMI spectrum)
  • Circuit‑level qualification: switching behaviour, current ripple, fault response
  • DFM/DFT reviews and critical‑path identification
     

Design Verification Test (DVT)

  • Full‑system evaluation under nominal, boundary, and fault conditions
  • Sub‑system interoperability (control + power + comms + sensing)
  • Stress‑margin validation for voltage, current, temperature, EMI, resonance
  • Issue tracking, root‑cause analysis, and configuration‑managed retest
     

Production Validation Test (PVT)

  • Application‑level operation in representative environments
  • Thermal cycling, environmental soak, mechanical stress screening
  • Combined‑stress HASS / HALT regimes (vibration + humidity + electrical load)
  • Qualification reports for production readiness, customer audit, and agency review
  • Manufacturing build validation against CTQ metrics

Environmental & Mechanical Qualification

We simulate and test physical durability under real‑world and edge‑case environments:

  • Thermal testing: steady‑state and transient with IR imaging
  • Thermal cycling & shock: powered / unpowered, –40 °C – 150 °C sweeps
  • Mechanical shock & vibration to SAE J1455, ISO 16750‑3, IEC 60068‑2‑6, MIL‑STD‑810H
  • Ingress & corrosion: IP66/IP6K9K spray, IP67 immersion, salt fog, chemical splash
  • Dust, frost, freeze‑thaw exposure
  • Handling & packaging qualification for transport and installation
     

Analysis tools include ANSYS® Icepak, Flotherm®, and vibration FFT logging; failure modes feed directly into FMEA updates.

Electrical & Functional Test Coverage

Systems are exercised across voltage, frequency, and fault scenarios:

  • Input/output stress: brown‑out, inrush, transients, ESD, surge
  • Power‑throughput characterisation: efficiency curves, line/load regulation, ripple/noise
  • Short‑circuit & over‑current: device shutdown timing, SOA validation
  • Fault injection: open‑loop, dead‑time, comm‑loss, sensor drift, watchdog recovery
  • Software V&V: ISO 26262‑6 ASIL‑targeted code, MISRA‑C:2012 compliance, Simulink Test™ traceability

EMI/EMC Compliance Testing

Device‑level switching and layout are correlated to emissions and immunity:

  • Conducted & radiated emissions and immunity scans
  • ESD, EFT, surge, and line‑dropout robustness
  • Grounding, shielding, and filter verification
     

Compliance frameworks supported:

  • CISPR 25 (vehicle), CISPR 32 (ITE), CISPR 11 Group 1 Class A
  • EN 61800‑3 (adjustable‑speed drives)
  • FCC Part 15 (consumer)
  • SAE J1113‑42 / ‑12 and ISO 7637‑2/‑3 transients
     

Up‑front PCB parasitic extraction, modulation‑noise prediction, and filter tuning minimize re‑spins.

Manufacturing Process Qualification

We bridge prototype to production with documented, standards‑driven processes:

  • Manufacturing standards: IATF 16949, IPC‑A‑610, UL, ISO 9001
  • Early DFM / DFT reviews and design updates (EVT stage)
  • Complete build package: BOM, PCB stack‑ups, 3D models, cable sets, test plans
  • Process‑specific qualification (reflow, selective solder, BGA X‑ray, coating, potting)
  • End‑of‑line strategy: ICT, functional test, burn‑in / ORT
  • CTQ metrics and PPAP Level 3 / 4 submission support

Tools & Infrastructure

We plan, execute, and track validation with an integrated toolset:

  • Simulation & analysis: ANSYS®, Flotherm®, SolidWorks® Simulation, Simulink®
  • Data acquisition: NI DAQ, CAN analysers, Python‑based logging
  • Requirements & test management: IBM DOORS Next / ReqIF traceability
  • Custom mechanical fixtures for shock, vibration, and flex tests
  • Automated reporting pipelines feeding issue‑tracking systems

Talk To Us About Your Project

Meet the Expert

Rod Watkins

Rod Watkins is MarSum’s lead in Design Validation & Process Qualification, with decades of experience in cross-functional engineering across power electronics and embedded systems. He specializes in:

  • Full EV-DV-PV gated validation programs
  • Reliability and compliance testing for mission-critical hardware
  • Manufacturing interface and CTQ documentation
  • Real-world failure mode analysis and design improvement

Rod has helped bring dozens of systems from concept to qualified production in highly regulated environments.

Contact Rod About Your Validation Requirements

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