A Tier 1 automotive powertrain manufacturer needed a set of precision test-interface fixtures to support production checkout of high-current components on the factory floor. The requirement called for build-to-print execution on a family of low-volume, high-mix mechanical-electrical subassemblies, with each one a critical link between the device under test (DUT) and the customer's checkout system.
The project scope covered a full probe-block fixture family, built to print from customer drawings:
Each assembly incorporated high-current test probes rated to 35A, solder-cup pogo-pin sockets, and copper bus bar for high-amperage pass-through — the kind of specialized componentry that standard test-fixture shops don't stock or spec correctly the first time.
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Every fixture moved through the same build-to-print discipline used across all custom electrical test system work:
To support the customer's on-site validation, dedicated checkout bay space was made available with both 400VAC and 480VAC power hookups to enable the customer to bring their own supporting equipment and run final acceptance testing on the finished fixtures before they went into production use.
A matched set of custom test-interface fixtures, built to print and delivered ready for high-current DUT testing on an automotive powertrain production line — precision-machined, correctly sourced, and validated before shipment.
Ball Systems creates, develops, and delivers custom test systems and produces comprehensive build-to-print systems for companies that craft or manufacture critical electronic or electromechanical components for aerospace and defense, automotive, and consumer appliance applications.
