Environmental Testing

Testing of Unmanned Systems – Aerial, Ground and Marine

BOSMAL provides comprehensive testing, validation and development support for unmanned systems intended for defence and special applications. The scope covers unmanned aerial, ground and marine platforms as well as their components and subsystems. Within a single R&D centre, we can verify structures, materials, electronics, power supply and propulsion systems, and resistance to environmental conditions. The offer is complemented by metrology, structural analyses, prototyping and the development of customised test programmes.

Technical data

Testing may include:

• EMC/ESD of electronics, electrical insulation, harnesses and connectors, and electrical parameters;
• battery-pack testing, charging/discharging, vibration and mechanical shock;
• electric propulsion testing;
• assessment of composites and structures, fatigue durability, material identification, microscopy and metallography;
• IP dust and water protection, thermal shock, extreme-temperature climate, humidity, rain, corrosion and ageing.

For marine systems, salt-environment and salt-fog exposure, corrosion and erosion, and pressure testing are also available. BOSMAL also provides metrology, prototype trials, structural analysis and customised test programmes. Defence-sector capabilities are confirmed by Defence & Security Accreditation No. 67/MON/2024, AQAP 2110:2016 and Polish Ministry of the Interior and Administration Licence No. B-138/2023.

Vibration and Mechanical Shock Testing

BOSMAL performs resistance testing of components, assemblies and devices under sinusoidal and random vibration and mechanical shock. Tests can reproduce real operating loads using recorded time histories. Vibration systems can operate with climatic chambers, enabling mechanical loads to be combined with temperature and humidity exposure. BOSMAL also provides design and manufacture of dedicated test fixtures and development of customised test programmes.

Technical data

Vibration systems: 36, 80 and 125 kN.

• 125 kN system: force 125 kN (sine/random), 360 kN (mechanical shock);
• frequency range 4–2000 Hz;
• max. displacement 100 mm;
• max. acceleration 100 g (sine/random) and 200 g (shock); max. payload 2000 kg;
• vertical table 1200 × 1200 mm;
• horizontal table 1500 × 1500 mm.
• Integrated climatic chamber: 2800 × 2500 × 1400 mm;
• temperature from −45 to +180°C;
• humidity 10–98% RH.

Testing includes IEC/EN 60068-2-6, IEC/EN 60068-2-64, IEC/

Vibration, vibroacoustic (NVH) and tensometric testing

Large-Scale Climatic and Environmental Chambers

BOSMAL tests vehicles, machines, equipment and components under controlled high- and low-temperature and humidity conditions. Large-scale climatic chambers enable testing of complete vehicles and other large objects, including special-purpose equipment.

Tests assess functionality, cold starting, durability and product behaviour under extreme environmental conditions. Individual temperature profiles and customised test programmes can be developed to meet customer requirements.

Technical data

• Two large-scale, free-standing climatic chambers, each 11.5 × 4.7 × 4.2 m.
• Chamber 2: temperature from 0 to +65°C; humidity up to 98% RH at 55°C.
• Gate size: 4.7 × 4.2 m.
• Additionally, three 11.5 m long chambers are available for conditioning and testing objects, particularly vehicles: temperature from −35 to +65°C; humidity up to 98% RH at 55°C; internal space 11.5 × 2.28 × 2.55 m. Chamber 1: temperature from −65 to +65°C; humidity up to 98% RH at 55°C. 

Functional and durability testing, as well as evaluation of starting and operation under extreme temperatures, can be performed.

Electromagnetic Compatibility (EMC) Testing

BOSMAL provides comprehensive electromagnetic compatibility (EMC) testing of electrical and electronic components for military, industrial and automotive applications. The new ALSE chamber enables assessment of conducted and radiated emissions as well as immunity to electromagnetic disturbances over a wide frequency range. The facility can also test large and high-voltage devices, with power supply, cooling and continuous functional monitoring available during testing.

Technical data

ALSE (Absorber-Lined Shielded Enclosure):

• usable dimensions 7.55 × 6.05 × 3.10 m;
• specimen mass up to 700 kg;
• frequency range 10 kHz–40 GHz;
• programmable DUT supply up to 1500 V DC / 2 × 500 A;
• cooling circuits, compressed air and communication interfaces;
• video monitoring

Scope: conducted and radiated emissions and immunity testing.

Compliance includes CISPR 25, ISO 11452 and MIL-STD-461G.

Additional RF immunity system: 100 kHz–7.12 GHz, field strength up to 600 V/m, with radar pulse and BCI capability.

See our technical capabilities

 

IP Protection Testing – Dust and Water Resistance

BOSMAL performs accredited IP protection testing for devices, components and assemblies exposed to dust, solid objects and water. The scope covers the full IP classification, from protection against access to hazardous parts and ingress of solid objects to rain, water jets, immersion and high-pressure washing.

Tests can be carried out according to international standards, manufacturer requirements or a customised test programme agreed with the customer.

Technical data

IP testing scope:

• IP1X–IP4X (protection against access to hazardous parts and solid objects), additional letters A–C;
• IP5X and IP6X according to EN 60529,
• IP5KX and IP6KX according to ISO 20653.

Water resistance:

• IPX1, IPX2 (dripping water), IPX3, IPX4, IPX4K (rain/spray), IPX5, IPX6, IPX6K (water jets), IPX7 and IPX8 (immersion), IPX9 and IPX9K (high-pressure washing).

Dust chambers: 1 m³ and 0.3 m³; 1 m³ chamber: 1000 × 1000 × 1000 mm, up to 100°C, optional negative pressure.

Immersion tank: Ø900 mm lifting platform, 1.5 m water column, adjustable water temperature, immersion depth and test duration.

High-pressure system: 30–120 bar, water temperature <80°C.

Standards: EN 60529/A2, ISO 20653, JIS D 0203, DIN 40050-9 and manufacturer specifications.

All BOSMAL IP tests are accredited under PCA AB 128.

Complementary water resistance tests are also available, including the Wading Test and High Pressure Cleaning with Thermal Shock.

IP-code. Protection against ingress of solid objects, dust and moisture

Engineering Design, Prototyping and Manufacturing

BOSMAL provides comprehensive design and manufacturing support – from concept and design assumptions through 3D modelling, engineering calculations and documentation to prototype manufacture, measurement, testing and implementation. The offer also includes special-purpose machines, test and measurement equipment and dedicated tooling. Combining an engineering office, manufacturing facilities, metrology and laboratories enables projects to be delivered from initial concept to a completed and validated product.

Technical data

CAD/CAE/CAM design, 3D models and 2D documentation; FEA including linear, nonlinear, dynamic, modal and coupled-field analyses.

Software includes CATIA V5, ANSYS 2024 R1, Siemens NX, Autodesk Inventor, AutoCAD, Abaqus, Solid Edge and Creo. CAM programming and 2.5/3/5-axis CNC machining.

Manufacturing capabilities include 3- and 5-axis CNC milling, conventional milling, turning, grinding, wire EDM and welding.

Production of models, mock-ups, prototypes, test and measurement fixtures, technological tooling and special-purpose machines.

Dimensional inspection with metrology reports, followed by verification and testing of the finished product.

See our technical capabilities

Material, Corrosion and Ageing Testing

BOSMAL provides comprehensive testing of materials, coatings and finished products to support durability assessment, quality verification and failure investigation.

The scope includes:

• material identification,
• mechanical and physicochemical properties,
• microscopy and metallography,
• corrosion and ageing tests,
• resistance to light and environmental exposure.

The laboratory also performs failure analysis to identify the mechanisms and root causes of defects in components operating under demanding conditions.

Technical data

Corrosion testing in artificial atmospheres: salt spray, immersion, condensation, SO₂ and climatic cycles; standards include ISO 9227, ASTM B117, ASTM G85, VDA 233-102 and ISO 11997-1/-2.

Testing in Cl₂, SO₂, NO₂ and H₂S atmospheres, with concentrations depending on the method up to 2700 ppb.

Material testing includes chemical composition, polymer and material identification, microscopy, metallography, mechanical and physicochemical properties and technical cleanliness.

Ageing tests cover temperature, humidity, ozone, UV, radiation and weather exposure.

Samples, coatings, components and complete products can be tested, including failure analysis.

Materials testing

Testing and Validation of Mobile Shelters and Temporary Shelter Facilities

BOSMAL provides testing, validation and development support for mobile, modular and container shelters as well as temporary shelter facilities. The scope may include structural safety, airtightness, environmental resistance, material durability, installations and equipment. Engineering and laboratory capabilities allow structural calculations and simulations to be combined with prototype and complete-module testing, supporting manufacturers from product development through technical validation.

Technical data

Scope: FEA and engineering calculations; load-bearing capacity, stiffness and deformation analysis; resistance to debris loads, blast wave, shocks and dynamic impacts; air- and watertightness tests and verification of positive/negative pressure retention; climatic, humidity, rain, dust, vibration, shock and fatigue testing; corrosion, UV, thermal cycling, chemical resistance and material analysis.

Largest climatic chamber: 11.5 × 4.7 × 4.2 m, standard operation up to +65°C.

Tow coupling testing according to UN Regulation No. 55 is also available. Reporting is performed in accordance with EN ISO/IEC 17025 where covered by accreditation.

Dynamic testing of mechanical shock and inertial loads on components and subassemblies

BOSMAL provides dynamic mechanical shock and inertial load testing with precise reproduction of specified acceleration and deceleration time histories. The test bench is intended, among others, for verification of the safety and integrity of rechargeable energy storage systems (REESS) and other components and assemblies exposed to severe dynamic loads. Testing can be performed according to applicable standards as well as customised load profiles agreed with the customer.

Technical data

The bench enables UNECE Regulation No. 100, Test 9C “Mechanical Shock”, and ISO 6469-1:2019, §6.4.1.1.2 “Inertial load at a vehicle crash”.

Parameters:
hydraulic actuator

• 400 kN force,
• 800 mm stroke;
• maximum speed 9.5 m/s;
• maximum specimen mass 600 kg including fixtures and instrumentation;

test table 2450 × 1450 mm.
Closed-loop control enables generation and iterative matching of specified acceleration/deceleration pulses.
Supported control-signal formats: dat, rsp, rpc, acq, tgt, mat, txt, csv. The bench can also perform other tests requiring precise reproduction of acceleration or deceleration time histories.