New Materials. New Questions: How Materials Testing is Keeping Pace

Properties of the materials being used across manufacturing have fundamentally changed, raising a new set of questions in the realm of materials testing. These stem from “will new physical attributes affect final product performance?” to “how will these new materials perform against proven and relied-upon industry standards?” (Figure 1)

Tinius Olsen enhanced methods for compliance and confidence in materials testing
Figure 1. Changes to material properties and characteristics throughout manufacturing are requiring enhanced methods to ensure compliance and confidence in materials testing.

In the face of this uncertainty, materials testing professionals are accessing better research and testing tools as well as standards that are evolving to properly evaluate new material formulations and performance characteristics.   Two particularly affected areas are additive manufacturing and recycled and composite polymers, both of which introduce a different set of variables into the processing of materials, which in turn affects materials testing principles.

Additive Manufacturing

Additive manufacturing is quickly moving from R&D into mainstream production, bringing with it a new set of materials, processes and performance variables. It’s becoming even more important to understand the molecular structure, thermal properties and post-processing function of these materials. No longer just about the finished product, there are several other manufacturing variables influencing material performance.

Superalloys in aerospace, power generation and other high-temperature applications require elevated temperature testing to ensure material strength and long-term durability as well as identify deformation under real-world operating conditions.  (Figure 2)

Figure 2. As additive manufacturing gains momentum, proper evaluation of next-gen material characteristics becomes crucial to ensuring reliability and upholding quality control.

The standards for evaluating these material characteristics are evolving alongside the technologies. For example, ASTM International’s Committee F42 on Additive Manufacturing Technologies evaluates more than 70 standards that directly impact additive manufacturing to ensure the methods, processes and qualification parameters are inline with this next-generation of materials. 

Some key standards the committee oversees include:

  • ISO/ASTM52900
  • ISO/ASTM52927
  • ISO/ASTM52931
  • ISO/ASTM52933
  • ISO/ASTM52949

Learn more about Committee F42, which is working to establish a testing environment that aligns with the material properties of today’s additive technologies as they become more prevalent in critical manufacturing applications.

Recycled & Composite Polymers

Melt flow is another area of materials testing where the old principles are being challenged by newer materials, both from recycled plastics and advanced composite formulations.  From resins, fillers and reinforcements to processing history, viscosity and flow behavior, each batch of plastics and polymers requires a careful eye on material properties and physical characteristics.  (Figure 3)

Figure 3. Today’s polymers can include a combination of recycled plastics, fillers and resins that introduce variables and change the physical properties of material used in manufacturing.
Figure 3. Today’s polymers can include a combination of recycled plastics, fillers and resins that introduce variables and change the physical properties of material used in manufacturing.

Parameters such as resin-to-reinforcement ratio and material formulation strength matter, especially when additives and recycled content are being introduced to raw material or reformulated batches.  Materials testing needs to accurately track what a change in resin formulation looks like or if process timing impacts fiber/filler loading as well as historical melt flow rates (MFR) to provide a predictive path for advanced composites and recycled plastics.

One area where melt flow testing is evolving is test equipment. Loadcell-based melt flow indexing (MFI) enables constant load, extremely detailed accuracy and improved observation when testing these new and inventive compositions.

An added benefit of the new digital system is operator safety, since manual weights are no longer required, and the calibration, testing and cleaning processes are all automated, while still being in full compliance with ASTM D1238 and ISO 1133-1.

Where Data Becomes Critical

The common thread across these changes in materials testing is better access to more detailed data. What do all these results mean? How can the industry use these insights to improve processes moving forward? The goal: develop stronger and more consistent batch-to-batch yield.

Software is the layer transforming disparte machine data into a unified library of information used throughout the materials testing process.  Not only do comprehensive platforms, like Horizon, improve reporting and analysis, they actually help streamline workflow, aid in research and development as well as increase traceability in manufacturing operations.  (Figure 4)

A comprehensive software platform by Tinius Olsen managing the materials testing environment gives professionals deeper access to data insights, which can be turned into useful trend analysis and operational efficiencies.
Figure 4. A comprehensive software platform managing the materials testing environment gives professionals deeper access to data insights, which can be turned into useful trend analysis and operational efficiencies.

Being able to recognize patterns and processing trends that facilitate informed decisions, for example, is a crucial advantage when working with new formulations, additives and composites.  Capturing and organizing test results along with specimen and batch data means easier comparisons and improved continuity. Deeper insights through networked data contribute to trends analysis and anomaly detection. Materials testing intelligence increases, leading to a stronger test environment.

Testing with Confidence

As the search for new, better and more effective compositions continues, materials testing professionals are tasked with staying ahead of the curve, and new formulations will introduce news questions.  Both the international standards organizations and test system manufacturers are stepping up to provide an enhanced set of parameters and tools that will ensure compliance and safety as material properties continue to evolve. 

Together, these resources forge a solid infrastructure that then incorporates a unified data network for an even more comprehensive and confident test environment. Materials will continue to evolve, but test engineers have the means to evaluate, measure and understand them.

Cost Efficiencies of Materials Testing for Improved Operations

Materials testing is one of the most valuable ways to ensure quality products by providing consistent, measurable results based on industry standards.

From the manufacturing plant and research laboratory to numerous universities and educational institutions, companies use materials testing to ensure product excellence, optimize efficiency, and prevent costly failures.  While every sector uses materials testing for different reasons, the goals remain consistent — improve product development and reliability.

An important, yet often overlooked benefit, is cost efficiency. By understanding the properties and behaviors of materials, organizations can make smarter decisions that drive long-term savings and innovation. (Figure 1)

Understanding material characteristics as well as environmental considerations significantly improves the cost analysis of production environments.
Figure 1. Understanding material characteristics as well as environmental considerations significantly improves the cost analysis of production environments.

Assessing Total Business Value

Across all markets, materials testing drives measurable economic and operational efficiencies, offering a powerful return on investment. Some of the most significant benefits include:

  • Reduced Material Waste: Optimizing processes ensures materials are used precisely where needed.
  • Minimized Product Failures: Testing helps prevent recalls, warranty claims, and loss of brand trust.
  • Boosting Production Processes: Fine-tune settings for maximum efficiency and minimal downtime.
  • Improved Product Longevity: Verified materials deliver better performance over time, reducing maintenance costs.
  • Accelerated Innovation: Validated materials help researchers bring new technologies to market faster and more cost-effectively.

A solid materials testing strategy will help in prioritizing and assessing what needs evaluation and when:

  • Critical, more costly, tests can be performed first to minimize rejected sample and expensive tests
  • Multiple tests can be run simultaneously on a given set of samples
  • Batched or representative sample sets reduce costs and testing time
  • Added automation helps to streamline operations
  • Documented testing maintains standards compliance

The effect is clear. Faster, more efficient testing means better throughput and less waste. With improved capacity, companies can evaluate more materials and design options.  The result is informed decisions that provide better insights and lower operating costs.

How Automation Contributes to Cost Efficiency

Automated materials testing is becoming a mainstay, with options ranging from semi-automated to fully autonomous systems. As these systems more deeply embrace data-driven architectures, companies can gain even more cost savings. Integrated software platforms, such as Horizon, provide test control, data collection, analysis, and reporting that improve quality records, enable easier audits, and reduce overall errors. (Figure 2)

Integrated software platforms are fueling automation-driven materials testing systems that improve testing accuracy and reporting.
Figure 2. Integrated software platforms are fueling automation-driven materials testing systems that improve testing accuracy and reporting.

Automated systems can run large volumes of specimens across more tests per day with limited or even no operator intervention or calibration needed in between tests. And test data can flow directly into the software platform.

The Role of Materials Testing in Manufacturing

For manufacturers and third-party testing facilities, materials testing forms the backbone of quality assurance. It ensures that every material used in production meets industry standards, regulations, and specifications.

A robust testing process starts by identifying potential weaknesses in raw materials before they reach the assembly line. This not only improves product performance and safety but also reduces the risks of defects, recalls, and warranty claims—issues that can significantly impact profitability and brand reputation.

But beyond quality control, materials testing helps streamline production efficiency leading to better cost optimization. By understanding how materials respond to factors such as stress, heat, or fatigue, manufacturers can minimize waste and improve throughput. For example, knowing the exact limits of a material’s tensile strength can prevent overuse, saving both time and resources.

Simply put, every dollar invested in testing up front can prevent thousands in lost production costs, warranty issues, or customer frustration later on.

Driving Research and Proving New Technologies

In research labs and universities, materials testing validates the performance of new materials and products—bridging the gap between theory and real-world application.

Insights into a material’s mechanical, thermal, and chemical properties allow scientists to assess potential uses, optimize formulations, and meet specific performance criteria. For instance, researchers developing advanced composites or materials rely on testing data to ensure those materials can withstand the conditions of their intended use.

Materials testing not only verifies what works, but also reveals why something works, leading to faster development cycles and more cost-effective R&D investments. The ability to identify issues early in the design phase reduces trial-and-error experimentation, shortens time to market, and ensures that resources are used efficiently.

In essence, materials testing is the key that unlocks innovation—turning promising concepts into reliable, scalable technologies.

Reducing Costs and Increasing Purpose

Materials testing is a strategic investment in quality, efficiency, and innovation. Not only can organizations realize substantial cost savings, but they can enhance their competitive edge. Whether ensuring the reliability of manufactured goods, validating breakthrough technologies in research, or driving discovery within universities, this critical testing infrastructure provides the foundation to support progress and improve cost efficiencies.

What’s Next?

Ready to optimize your materials testing process to save time and money?  Check out The Many Roles of Automated Material Testing (AMT) in Manufacturing white paper for more insights.

2026 Technology Trends Affecting Automation in Materials Testing

Automation, long a fixture of the production floor, has made its way into the materials testing environment across virtually all manufacturing sectors, from automotive and aerospace to medical devices and advanced polymers.

Materials testing equipment is no longer just a set of passive machines. Instead, the testing landscape is transforming into one where intelligent, integrated systems not only manage the testing process, but form a network that influences manufacturing operations and production efficiencies in near real time.

In addition to verifying materials’ performance and ensuring safety specifications, automated testing provides new means for innovative materials research as well as optimum production environments. The impact reaches well beyond simple data analysis and efficiency gains. Automation is the fundamental step for teeing up a materials testing environment to embrace an AI-enabled ecosystem. (Figure 1)

Integrating automation technologies
Figure 1. Integrating automation technologies sets the stage for a more comprehensive AI-based materials testing environment.

Digital Technologies Trends

In today’s manufacturing environments, you’d be hard pressed to find a company without a plan that includes some degree of AI implementation. Although materials testing has traditionally sat a bit apart from the manufacturing environment, today’s digitally-based equipment and advanced data sets are quickly becoming a streamlined part of facility operations.

But technology adoption should happen at the rate that makes sense for your test environment. A great place to start is to take stock of the available technologies and existing processes and see where you can make immediate improvements in your process versus planning for some more long-term investments.

Here we examine some trending technology shifts fueling automation adoption throughout materials testing:

Closed-loop control. Not new, but expanding, closed loop control allows for continuous monitoring and real-time load adjustment.  Systems using digital technologies can respond dynamically to how a material truly behaves rather than simply applying force at a fixed rate, for example. A recent implementation is the loadcell-based MP1500 that eliminates the need for a deadweight system in melt flow indexing and incorporates a closed-loop control system. (Figure 2)

Tinius Olsen Closed loop technology
Figure 2. Closed loop technology continues to be a driving force in automated materials testing environments. (Pictured: Loadcell-based MP1500 MFI)

Extensometry. Contactless extensometry is making strides. One example is the UVX3D that not only removes the awkward useability issues of traditional units but offers elevated or enhanced technical performance that supersedes single-camera units. This extensometer captures a video stream and replays it with the digital strain data embedded for analysis and use, essentially allowing the user to replay the test.

A new class of extensometry is also emerging with the Vector, which serves as a cost-effective replacement for virtually any clip-on type of extensometer currently available. Its underlying AI-based technology has initiated a game-changing shift by turning the testing machine zone into a digital representation. Test events can easily be measured across large, small and even non-uniform specimens, with a simple, no-touch set up.

Integrated software. Highly sophisticated software platforms are not just observing what test machines are doing, but are helping to direct the process, serving as an extension of the test environment itself.  The functionality goes far beyond simple data collection to include automation control, data management, and reporting capabilities that provide faster, deeper insights into material characteristics.  These advanced software platforms are facilitating large-scale integration across system processes and providing easy access to more comprehensive and intuitive analysis.

Take the Horizon platform that exemplifies this forward-looking strategy to elevate the materials testing digital landscape. Instead of requiring a full system overall, the software is structured in modules that allow users to implement technology upgrades where and when it makes sense, and only for the test and results needed. This inherent flexibility is the cornerstone of an automated testing environment, as it enables labs and manufacturing facilities to keep pace with technology advancements without sacrificing standardization or operational efficiency. (Figure 3)

Tinus Olsen Software Platforms
Figure 3. No longer just a means to collect data, software platforms are optimizing machine control, data analysis and process efficiencies for large-scale integrations.

Multi-machine Systems. Some may consider this more of an outcropping of software technology advancements, but systems that run multiple machines simultaneously are being built, needing just one operator to  oversee what used to be several, disparate test stations. As digital tools and technologies continue to fuse, a more networked infrastructure is becoming the norm, with a look towards multi-faceted test environments that are more integrated, optimized and cost-efficient.

Tinius Olsen offers a scalable, modular method of technology insertion that helps customers in their path to automation, on a timeline and within a budget that makes sense. This approach ensures that updates and investments keep pace with the test environment, whether it includes tensile, compression, flexural, impact, melt flow, hardness tests or another testing protocol.

Standards Still Reign as Technology Advances

Whether the goal is to determine the tensile strength of a structural alloy, characterize the flexural behavior of a fiber-reinforced composite, or evaluate the melt flow properties of a new batch of resin, materials testing is not a trivial process. Every test is governed by strict international standards that specify not just what to measure, but exactly how.

ASTM, ISO and other governing standards organizations remain essential to ensure consistent, repeatable and comparable results across different test environments and regions. Automation serves to facilitate the process and optimize the data, but standards provide the framework for reliable, universally repeatable results. Any automated testing platform needs to stay aligned with industry protocols, so that the measurement ecosystem, which includes calibration methods, sample handling, data analysis, test environments, and more, still follows these critical standardized methods.

The State of Automated Materials Testing

Automation is not simply about speed. It is about optimization, efficiency and integration. What was once a largely passive, machine-based process is evolving into an intelligent, interconnected ecosystem that influences manufacturing operations in near real time. Taking stock of trends today will prepare you for the materials testing environment you want tomorrow.

To learn more about what else is happening in the automated materials testing environment, download The Many Roles of Automated Material Testing (AMT) in Manufacturing white paper.