It is very common for products and packages to be accidentally dropped during shipping, handling, or other accidents during their daily use, regardless of whether it is due to carelessness. Drop testing attempted to simulate these circumstances in a controlled laboratory environment to assess how a product attenuates and disperses the impact energy. In whatever device is tested, whether a smartphone, a glass bottle, or an engineering part, drop testing reveals weaknesses in the construction and enables engineers to determine how best to optimize materials, geometry, and packaging to be designed for failure. This is what is commonly known in product validation guidelines and is primarily used to optimize importation and domestic shipments, as well as quality assurance procedures.
Methodology of Drop Testing
The test consists of dropping a product or its packaging from a certain height onto any hard surface, which is often repeated several times and in different positions (flat, corner, or edge). The height and type of surface utilized in the drop are based on the relevant standards (ISTA, ASTM D5276, or Mil-Std-810). Each drop is inspected to analyze functional damage, cosmetic defects, or structural failure in test specimens. Operational testing can be completed after the manufacturing of precision devices to ensure performance is not compromised. High numbers of drops can be applied to represent prolonged use or manipulation.
Instrumentation of Drop Testing
Drop testing is performed using drop test machines, which allow for precise control of the height, angle, and surface of the drop. Testing devices include basic free-fall testers up to programmable orientation and velocity control testers. Impact force, velocity, and deformation can be recorded in real-time using sensors, cameras, and data loggers.
Strengths of Drop Testing
The use of drop testing is practical and realistic, as it allows you to test the resistance of a product to the impact associated with handling. It is simple to carry out and yields convenient outcomes in the design of products and materials used. Its performance is enhanced by protective packaging during delivery, resulting in cost savings due to reduced damage. It also enhances consumer confidence since the ruggedness claimed will be proved in any product advert.
Limitations of Drop Testing
Drop testing is also a destructive method, and it is impossible to test all the other possible conditions of real life unless several angles and surfaces are tested against. This could vary when the positioning or even the internal positioning of the product is altered, and this would have to be done numerous times to obtain accurate figures. However, normal tests in drops are short-term (impact) tests, and none of the fatigue or repeated minor impacts are considered unless other mechanical tests are also conducted simultaneously.
