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Integrated Test and Inspection

Ensuring the reliability and performance of your products

Key Differentiators

Unlocking product quality with the Plexus approach

Leveraging advanced testing capabilities

We use cutting-edge technologies like X-ray, in-circuit and functional testing to thoroughly scrutinize your product, Our comprehensive capabilities ensure unparalleled defect detection and a complete understanding of its performance and durability.

Delivering data-driven insights for continuous improvement

Our testing collects and analyzes critical data, providing actionable insights that optimize processes and predict future performance. This approach drives continuous quality improvement and greater efficiency throughout your product’s life cycle.

Assured compliance and risk mitigation

Our integrated processes are built on a foundation of rigorous compliance, ensuring your product meets stringent industry standards. We proactively mitigate potential quality risks, safeguarding your reputation and accelerating market acceptance.

capabilities

Our integrated test and inspection capabilities

Inspection Services

We visually and structurally inspect products to detect defects early, ensuring the highest quality standards before further processing. This includes non-destructive X-ray inspection for complex components with hidden connections, as well as automated vision systems that precisely verify physical attributes like component placement and polarity.

Functional and Electrical Testing

We verify the electrical integrity and operational functionality of your product to ensure it performs exactly as designed. Our comprehensive methods range from in-circuit testing to check component values and connections, to flexible flying probe technology, and full functional testing that simulates the product’s final operating environment.

A Plexus employee working on a machine for failure analysis

Reliability and Failure Analysis

Our services are designed to improve product durability and provide critical insights into performance issues. We use Highly Accelerated Life Test (HALT) and Highly Accelerated Stress Screening (HASS) to subject products to extreme stresses and uncover weaknesses, significantly enhancing long-term reliability. When failures do occur, our dedicated failure analysis lab investigates the root cause, providing valuable data for continuous improvement.

Two Plexus employees looking at a screen

Quality and Traceability Management

We provide the data management tools necessary to ensure accountability and control throughout the entire manufacturing process. Our end-to-end traceability tracks every component, process and test result from procurement to final shipment, creating a comprehensive data trail for quality control and swift action.

faqs

Frequently asked questions about integrated test and inspection with Plexus

Plexus specializes in testing highly complex and miniaturized electronic assemblies and systems. Our advanced integrated test and inspection capabilities, including cutting-edge X-ray, automated optical inspection (AOI), in-circuit test (ICT), and functional test (FCT), are designed to detect even the most subtle defects in dense, intricate designs. Our expertise ensures reliable performance for the most demanding applications.

Plexus maintains rigorous adherence to a comprehensive set of industry standards and regulatory requirements. This includes, but is not limited to, ISO 9001 (Quality Management), ISO 13485 (Medical Devices), AS9100 (Aerospace), and IPC standards (e.g., IPC-A-610 for Electronics Acceptability). Our robust quality management system ensures all testing and inspection processes are compliant, providing the necessary documentation and traceability for your product’s specific industry regulations.

Seamless integration is a core strength of our approach at Plexus. While we offer full end-to-end manufacturing, our integrated test and inspection services can be strategically implemented within your existing manufacturing processes. We work collaboratively to understand your current workflows, identify optimal integration points and ensure our advanced testing capabilities enhance your production line, providing critical quality gates without disruption.

Contact our team

Ready to elevate your product’s quality and reliability?