• The fixture is finally working. The measurements are stable. The limits are all set.
• The PLC handshakes don’t fault out. Operators are trained, and parts are flowing.

Everyone celebrates because they should. Getting a new EOLT station deployed is hard work. But then something predictable happens: All the long-term improvement ideas, especially around data management, get pushed to “Phase 2.”

“We’ll come back to the data piece later.”

“Let’s get production stabilized first.”

“We’ll handle reporting in the next budget cycle.”

Except… “later” almost never comes. Once the line is running and hitting daily takt numbers, the momentum shifts to the next urgent project. The data pipeline, how results are stored, validated, structured, analyzed, or even found later, quietly fades into the background.

Meanwhile, the EOLT system is generating an enormous amount of valuable information. Every single test run produces signals that could help improve capability, reduce escapes, diagnose warranty returns, or drive Six Sigma improvements. But unless someone deliberately builds a usable data pipeline, those insights disappear into a pile of CSV files, neglected SQL tables, or are not collected at all.

This blog is about that forgotten half of EOL testing, and what you can do to finally unlock the value that’s already sitting in your factory.

Why EOL Data Is So Important, and So Underutilized

There’s often a huge gap between what leaders think is happening with EOLT data and what’s actually happening on the ground. The expectations typically sound like this:

“We’ve been keeping our test data stored somewhere.”

“It can be accessed by Quality whenever required.”

“We’ll be using this data for SPC once we stabilize production.”

“There’s another project that will be following this one to create dashboards.”

“This data has been cleaned and sorted already.”

In theory, the data is being scrubbed, validated, indexed, archived, and correlated with part numbers, revisions, and operators. And ultimately, used to improve the business. But the reality is usually very different. In most factories, this is what actually happens:

• Data is saved in inconsistent formats by different test stations and engineers.
• Pass/Fail Limits are not version-controlled.
• SQL tables live on a local PC with no backups.
• CSV files pile up in folders named “temp,” “new,” or “old system”.
• Dashboards and data portals never get built.
• Phase 2 never gets funded.

And even when data is stored, it’s often impossible to use:

• Test records include missing or mismatched fields.
• Metadata (revision, operator, equipment ID) is missing.
• Time stamps are inconsistent or incorrect.
• No one knows how to open a *.TDMS file.
• Data is unvalidated, unstructured, and untrustworthy.

Engineers want to use EOL test data, but the pipeline isn’t there. The result, EOLT data becomes “digital exhaust” instead of actionable insight.

What’s most concerning isn’t the volume of information generated, but the value it represents. Every EOLT run provides a window into the capabilities of your process, the state of your design, and the variance in your manufacturing operation. Essentially, it’s the best way for you to keep an eye on the quality of your manufacturing process.

However, without a defined path to capture, structure, and analyze this data, its value is lost, leaving critical insights on the production floor.

What You Could Be Doing with Your EOL Test Data

Your End-of-Line tester should do more than just tell you whether a part passed or failed. When that data is captured, organized, and connected across teams, it can become a powerful tool for improving quality, reducing waste, speeding up production, and making better engineering decisions.

A few of the highest-value ways to use EOL test data include:

• Catch process drift before it becomes a problem – By tracking key measurements over time, teams can spot trends, shifts, or out-of-control conditions before they lead to scrap, rework, or customer escapes.
• Understand whether your process is truly capable – Capability studies help show whether your process is consistently meeting specifications—not just passing tests, but doing so with enough margin and stability to build confidence.
• Make better decisions with trusted measurements – If the measurement system is not repeatable or reliable, the data can point teams in the wrong direction. Connecting MSA data with production results helps prove that the numbers can actually be trusted.
• Enhance testing boundaries and eliminate false failures – Information from previous EOL results can help a team improve their testing parameters, strengthen their weak spots, and ensure they don’t reject good items. It also helps to establish an audit trail for parameter changes.
• Reduce cycle time by removing low-value tests – Not every test adds equal value. By looking at fail rates, test duration, and correlation to real defects, teams can identify tests that may be redundant, rarely useful, or candidates for consolidation.
• Connect factory results to warranty and field issues – When EOL records are linked to returned parts or field failures, teams can identify early warning signs present during production. This can reduce warranty costs and help engineering improve future designs.
• Give each team the information they actually need – Operators, quality engineers, line leads, and product engineers all need different views of the same data. Role-specific dashboards and alerts help make sure the right people see the right information at the right time.
• Limits, set-ups, and software releases – It would be far more valuable if all EOL data could be tied to the specific test limits, set-ups, and software releases actually used during testing.

EOL test data is not just output data. When effectively utilized, it serves as a tool for process improvement, helping teams to enhance quality, minimize variations, reduce cycle times, and make sound product decisions.

The Reality: EOL Data Only Works If the Pipeline Works

Even the best measurements, fixtures, instrumentation, and limits won’t produce value if the data pipeline behind them isn’t healthy. And this is where most organizations quietly struggle.

An EOL test system is constantly generating signals: currents, voltages, timings, displacements, communication messages, temperatures, pressures, waveforms, vision metrics, operator interactions, PLC handshakes… the list goes on. But unless all of that information moves through a clean, reliable, structured pipeline, it becomes impossible to trust, access, or analyze later.

Most companies assume the pipeline will “take care of itself.” In practice, it does not. It requires planning, effort, and maintenance. Experience helps.

What a Healthy EOL Data Pipeline Requires

A robust pipeline needs several well‑defined components working together:

1. Reliable Data Capture – Every test must record the same fields, in the same format, with the same metadata. No missing values. No mystery columns. No different units for the same measurement.

2. Standardized, Versioned Test Records – Measurements, limits, station configurations, fixture revisions, and software versions must all be captured and traceable. When a number shifts, you need to know whether the product changed or the test changed.

3. Automated Reporting and Alerts – Data and analysis are worthless if no one sees it. A good pipeline pushes insights out automatically; it never waits for someone to “go pull the numbers.”

4. Clean, Structured Storage – Data needs to live somewhere durable and queryable (SQL, Azure, AWS, SystemLink, etc.). Not on a local PC. Not in a trove of CSVs on a network share. Not in arbitrary Excel files named “latest_results_FINAL2.xlsx.”

5. Full Traceability – Every record should connect back to the basics. Without this, you can’t trust the results: Serial number, Product revision, Limit set ID, Station ID, Operator, Test sequence version, Part configuration, Time and date, Equipment calibration status, etc.

6. Automated Data Validation – Bad records should be flagged at the moment of ingestion, not discovered months later during a recall analysis.

7. Easy Access for Those Who Need It – SPC needs Quality. Throughput/FPY needs manufacturing. Distributions/histograms need engineering. CAN logs need controls. Yield trends need leadership. Varied needs from varied perspectives, but they all point back to the same source.

Why Most Factories Don’t Get This Right

The underlying issue is simple: making the tester work gets all the attention, making the data pipeline work gets whatever scraps are left.

And typically, that means:

• Data “storage” is whatever the test automation vendor has implemented.
• Organizational structures evolve organically over the years and engineers’ careers.
• Important metadata is missing because it wasn’t captured from day one.
• EOL software revisions shift quietly without updating version fields.
• MES/ERP integrations never happen.
• Dashboards get deprioritized because “production is up.”

As products change, limits evolve, stations age, and operators come and go, the data slowly becomes inconsistent and disconnected. The further you go without a structured approach, the harder it becomes to fix the past, and the less likely the data will be trusted for meaningful decisions.

When the Pipeline Fails, Everything Downstream Fails

Without trust in the data, there’s no way to perform SPC analysis, capability study, limit adjustment, detect drift, troubleshoot warranty claims, shorten cycles, increase yield, or influence future design generations. Or, put differently: poor-quality data feeds make your cutting-edge EOL tester worthless – just a fancy go/no-go light.

And that’s a waste of capability and money. The moment you treat the EOL data pipeline like a business-critical process, test results transform from something that needs to be stored to something that can be learned from.

Why Companies Don’t Fix This, and Why They Should

1. EOL data projects are important, but rarely feel urgent

Most companies understand that better EOL data would help, but it often loses to more visible priorities like getting the line running, hitting takt time, passing audits, and shipping product. The problem is that once production stabilizes, “Phase 2” data improvements are easy to forget. By then, months or years of valuable production history may already be missing, inconsistent, or unusable.

2. Ownership is often unclear

EOL data usually sits between multiple groups: Quality, Manufacturing, Test Engineering, IT, MES vendors, and sometimes the system integrator. Because no single team clearly owns the data’s structure, quality, and usability, everyone assumes someone else is handling it. The result is fragmented data that may exist somewhere, but is not trusted or useful enough to drive real decisions.

3. Fixing the data pipeline is often one of the highest-ROI improvements available

Improving an EOL data pipeline usually costs far less than buying a new test system, but it can unlock major value: higher yield, lower scrap, better traceability, smarter test limits, shorter cycle times, and stronger warranty/root-cause analysis. When capital budgets are tight, this can be one of the smartest ways to get more performance out of the equipment a factory already has.

Conclusion: Stop Letting EOL Test Data Go to Waste

You don’t need a new tester to get new value. If your End‑of‑Line station is running but your data isn’t structured, trusted, or visible, you’re leaving yield, quality, and warranty savings on the table.

The fastest ROI today comes from transforming your EOL results into a clean, reliable pipeline that feeds SPC, capability, dashboards, and decision makers. It’s affordable; it doesn’t disrupt production, and it works with the equipment you already own—making it a smart move in tight capital years.

Maximize impact, treat the EOL data pipeline like a business process: capture consistently, validate automatically, store centrally, version limits/configurations, and surface insights to the right people. When you do, your tester stops being a pass/fail gate and becomes a continuous improvement engine.

Ready to explore our solutions? DMC specializes in modernizing EOL data without ripping and replacing hardware:

• Stand up a standardized results schema (with limit/config/software versioning)
• Build ingestion + validation pipelines from your existing testers
• Create SPC, capability, FPY, and spec margin dashboards
• Automate daily/weekly reports and alerts for quality and engineering
• Connect to MES/ERP and warranty/returns for closed‑loop learning

DMC’s Test & Measurement team routinely works in the latest test technology to help our clients uncover the value hidden in EOL test data. From NI software to Microsoft SQL Server, Ignition, Grafana and more, DMC can help you turn test data into a business intelligence asset.

The post End-of-Line Test: What to Do with All that Data? appeared first on DMC, Inc..

At DMC, we see these challenges firsthand through our work with a wide range of manufacturers in different industries. Our team designs custom test solutions that meet demanding performance requirements while remaining practical, cost-effective, and scalable. By focusing on adaptability and reliability, we help operators build test systems that support the needs of today while looking forward to tomorrow.

Why Testing Matters More Than Ever

A well-designed PCB and PCBA test strategy does more than test products at the end of the line. It supports quality, throughput, and futureproofs manufacturing operations as they continue to scale and evolve:

• Quality Assurance: Catch defects early to avoid costly downstream failures.
• Throughput Optimization: Keep your line moving without sacrificing accuracy.
• Compliance & Traceability: Meet industry standards and maintain audit-ready records.
• Lifecycle Adaptability: Design systems that adapt as your product mix evolves.

There are many reasons today for manufacturers to take a flexible approach when building a test system. Flexibility allows manufacturers to balance precision with speed, validating each unit without bottlenecking production. Automated test solutions also enable constant measurement, surfacing issues before they impact final assembly or the field. This approach not only improves first-pass yield, it also shortens feedback loops.

It’s equally important that modern test platforms are built for change. As products evolve and regulations shift, operators need test systems that can scale easily, integrate new test points, and support expanded data collection without a full redesign every time. Flexible, software-driven architectures make it easier to maintain compliance and protect your testing investment.

DMC’s Approach: Expertise + Flexibility

What sets DMC apart? Deep in-house expertise, industry certifications, and best practices, combined with strategic partnerships. We’ve built relationships with leading fixture manufacturers, instrumentation vendors, and automation specialists. This allows us to deliver end-to-end solutions tailored to your requirements, or any specific pieces of the system you need:

• Fixturing Options: From full bed-of-nails (BoN) systems for high-volume lines, to cost-effective connector-based fixturing solutions for smaller runs.
• Instrumentation: Modular, serviceable, and upgradeable DAQ and rack-based instruments sourced from trusted partners, and selected based on your needs and requirements.
• Software: Several customizable platforms ready to deploy and meet your current and future needs.
• Peripheral Systems: From simple barcode scanners, printers, & PLC automation interfaces to add-on services like MES integration and analytics platform design and delivery.

Fixturing: The Foundation of Reliable Testing

Whether your Device Under Test (DUT) is a bare PCB, a PCB assembly, or a fully enclosed PCB, your connection strategy drives cost, reliability, and timing. DMC can offer consulting and execution for:

• Complete Bed-of-Nails Fixtures: High-reliability, low-cost, or well-balanced systems can be sourced from multiple DMC partners.
• Cost-Sensitive Alternatives: DMC can offer in-house-designed and built fixturing or pogo-pin connector-based systems to reduce your spend.
• Automation Options: Robotic or auto-loading systems for high-throughput environments.
• Flexibility for Low-Volume, High-Mix Assembly: Quick-change fixtures and adaptable test sequences.

Test System Architecture: Built for Your Needs

Every system we design can be tailored to your application and include the components needed to support reliable, efficient testing, including:

• DUT Connections & Fixturing: Based on your project needs.
• Instrumentation: High-power, high-current, and high-voltage measurements are our specialty.
• Overall System Integration: Turn-key workbenches and/or racks with integrated fixtures and peripherals, to cost-saving, simple enclosure-based systems to add to your workbench.
• Software: Modular, intuitive GUIs that make operation simple, and test-engineering-friendly test sequence and parameter modification.
• Peripheral Integration: Barcode scanners, printers, databases, MES, analytics, and more.

For low-volume, high-mix operations, we can often recommend a single flexible test system that supports easy fixture changeovers and multiple DUT configurations, a real cost saver.

Advanced Capabilities

• Multiplexing: Reduce instrumentation costs and/or support multi-DUT setups with smart switching topologies.
• Microcontroller Programming: Need PCBA flashing station capability in your test system? We’ve got you covered.
• Scalable Design: If needed, DMC’s flexible designs let you start small and expand as your needs grow.
• Non-Standard Measurements: From magnetic and optical sensing to RF and high-power applications, we take on complex PCBA test challenges others may avoid.

Software That Works for You

DMC software solutions are not one-size-fits-all; they’re built to deliver speed, flexibility, and futureproofing in one package. With ready-to-deploy base designs and a wide range of platform tools at our experts’ fingertips, we can get your custom application up and running quickly, reducing downtime and fortifying your system for the future. All of our platforms and tools are designed with future flexibility and integration in mind, helping to ensure system effectiveness as demand and technologies change:

• Ready-to-Deploy: Base designs and a wide range of platform tools allow us to get your test software up and running quickly.
• Customizable: DMC can quickly add the software features you need now, while our modular platform tools allow you to grow as your requirements evolve.
• Future-Proof: All of our software platforms and tools are designed with your future flexibility and integration needs in mind.

We can also walk through GUI examples and provide live software demonstrations to show how powerful and intuitive our systems are. For a deeper look at one of our platforms, see The Hidden Cost of One-Off Test Systems.

Why Choose DMC for Test and Measurement Solutions?

DMC has a proven track record with major US manufacturers, supporting their complex test and measurement challenges and shifting technology needs. With multiple regional offices across the country, DMC is able to provide coast-to-coast support wherever our clients operate.

In addition to deep test and measurement expertise, our team also specializes in non-standard measurements and challenging test scenarios, partnering with leading instrumentation vendors to deliver reliable results.

Whether our clients are looking for a complete, turnkey system or modular components that fit within an existing strategy, DMC adapts every approach to meet business goals and project needs.

The post Adapting Manufacturing Operations? Flexible PCB and PCBA Testing Is Key to Success  appeared first on DMC, Inc..

That’s why early engagement with a test system integration partner matters. Whether you operate in the automotive, aerospace, energy, semiconductor, medical devices, or consumer electronics, involving the right partner early can reshape your project’s trajectory, reducing costs, enabling innovation, and accelerating delivery.

Early Input Leads to Smarter Test Strategy

Engaging a system integrator like DMC early in the project lifecycle helps teams make better decisions sooner. During the exploratory phase, DMC provides critical insight into test requirements and system architecture, informing on project scope, uncovering cost-saving opportunities, and aligning test capabilities with production and program goals.

In one recent project, early discussions led to the decision to split a complex end-of-line test process across multiple stations. This modular approach allowed the customer to better utilize their most expensive asset (high-power battery cycling equipment) by moving test processes that do not require high power to lower-power, lower-cost stations. The result was a more efficient test flow and significant capital savings.

In another case, DMC’s Test and Measurement team proposed a high-power multiplexing system that reduced the number of test assets needed to meet production rates. By automating these connections with well-designed software, the team effectively shared the high-power, high-cost equipment across multiple test stations, saving the client over a million dollars.

And in a third example, a DMC customer initially requested a bed-of-nails test system for a printed circuit board assembly (PCBA). After initial discussions, DMC engineers learned that the test’s purpose was a basic functional checkout prior to further assembly. All required tests could be performed through the already-installed PCBA connectors. DMC eliminated the need for an expensive bed-of-nails fixture and replaced the device-under-test (DUT) connection with a cable harness terminated in custom-designed, high mating-cycle, pogo-pin style connectors. This simple change, along with a reduction in DAQ system precision and accuracy requirements, cut hardware costs by 50 percent.

Phase 1 Exploratory Projects Reduce Risk and Clarify Direction

A Phase 1 exploratory project gives you a low-risk way to validate assumptions before committing to major capital or locking in system requirements. These engagements are typically short, fixed-cost engineering efforts focused on answering the right questions early, when changes are still inexpensive.

During Phase 1, DMC works with your team to:

• Clarify test requirements and production constraints
• Evaluate multiple system architectures and test strategies
• Identify cost, schedule, and scalability tradeoffs
• Define a clear path from prototype to production

In one example, a one-week engineering sprint helped a client define requirements and lay out two test system concepts: an initial system to support early builds and a scalable production system for higher volumes. This early clarity informed capital planning, aligned stakeholders, and prevented costly redesigns later in the program.

Phase 1 projects are intentionally flexible. You can move forward with full implementation, adjust scope, or pivot entirely based on what’s learned. Regardless of the outcome, you gain a clearer understanding of risks, costs, and long-term implications. Early collaboration sets the stage for smarter decisions. Clients can choose to proceed with full implementation or pivot based on feedback from their integration partner, setting the foundation for a test system that meets today’s needs without limiting future growth.

Broad Expertise and Strategic Insight Across Industries

While some examples stem from battery testing or electronics, the same principles apply across industries. DMC’s engineers bring experience from hundreds of test system deployments across major industries and relationships with suppliers of emerging test and measurement technologies.

By engaging early, you gain access to lessons learned across platforms and applications, including:

• Selecting the right instrumentation and switching topology
• Designing scalable software architectures built for change
• Integrating safety-rated systems and compliance considerations
• Consideration of emerging test and measurement technologies

The cross-industry perspective of a test system integration partner can help you avoid common pitfalls and build systems that are cost-effective, flexible, and ready to evolve.

Conclusion: Don’t Wait, Engage Early

If your team is planning a new test system or preparing for a major upgrade, don’t wait until specifications are locked or problems surface on the production floor. Early engagement with a test system integration partner gives you better options, clearer tradeoffs, and fewer surprises.

Whether it’s a short exploratory project or just an initial conversation, involving DMC early can help reduce risk, control costs, and design a test strategy that scales with your program. The difference between a good system and a great one often comes down to decisions made at the very beginning.

The post It’s Never Too Early to Engage With Your Test System Integration Partners appeared first on DMC, Inc..

If you’ve browsed our recent Test and Measurement case studies, you might notice that semiconductor projects aren’t front and center. There’s a reason for that, and it’s not because DMC can’t or won’t do them. For decades, semiconductor manufacturing and its associated test system development largely moved overseas. As fabrication and assembly plants shifted to Asia, so did the capital budgets for automated test equipment. U.S.-based system integrators like DMC naturally focused on industries where investment remained strong: automotive, aerospace, energy, and medical. 

What’s Changing Now? 

The tide has started turning. With initiatives like the CHIPS Act and renewed focus on supply chain resilience, billions of dollars are flowing back into U.S. semiconductor manufacturing. New fabrication and advanced packaging facilities are being built here at home, and these projects come with serious capital budgets for automation and test systems. This resurgence means the need for robust, flexible, and scalable test solutions is greater than ever.

We’ve Done This Before, and We’re Ready to Do It Again 

Although recent years have seen fewer semiconductor projects, DMC has a history in this space. Check out these classic examples from our archives: 

• Fiber Optic Data Transmission Test System
• Silicon Wafer Processing
• Burn-In Test System for Fiber Optic Devices
• Process Control System for Film Deposition Tool

These projects demonstrate our ability to design and implement automated test and process control systems for high-tech manufacturing like semiconductor and telecom manufacturing environments. Engineers who worked on these systems are still with DMC, and they’d love to dust off their semiconductor expertise and apply it to modern challenges using today’s tools. 

Why DMC Is a Great Fit for Semiconductor Test Automation 

• Deep Automation Expertise: From PXI-based test stands to MES integration, we know how to build systems that scale. 
• Modern Tools & Frameworks: NI TestStand, LabVIEW, Python, .NET, and custom frameworks like DMCquencer and CORTEX. 
• Industry Knowledge: We understand the critical importance of yield, traceability, and uptime in semiconductor manufacturing. 

Let’s Build the Future Together 

If you’re planning a new fab, upgrading a process line, or are supporting one, and you need automated test systems for semiconductor devices, DMC is ready to help. We combine decades of experience with cutting-edge technology to deliver solutions that meet your performance, reliability, and compliance requirements. 

The post Does DMC Do Automated Test Systems for the Semiconductor Industry? appeared first on DMC, Inc..

When it comes to reliability, every component in your power infrastructure matters. UPS systems, battery backups, switchgear, and backup generators all play a role in keeping operations online. But here’s the catch: testing individual components isn’t the same as testing the entire system. Each piece can pass its own validation, yet the integrated system may still fail under real-world conditions. Failure modes often emerge only when these components interact under load, during transitions, or in response to unexpected events.

Why Testing Matters 

Downtime in a data center is costly and sometimes catastrophic. Power systems are complex, and their performance under stress determines whether your facility can deliver on its uptime promises. Yet many projects rely on manual checks or incomplete testing strategies that leave gaps.  

Consider these questions: 

• Are your UPS systems validated for transient response during failover? 
• Has your switchgear been tested under realistic load conditions? 
• Do your backup generators respond correctly during commissioning? 
• Is your battery management system (BMS) ready for real-world charge/discharge cycles? 

If you’re not confident in the answers, you’re not alone. Many teams assume that OEM testing or basic commissioning is enough. It probably isn’t. 

Where Testing Should Happen 

Comprehensive testing should occur at multiple stages: 

• Factory Acceptance Testing (FAT) – Validate performance before equipment leaves the OEM 
• On-Site Commissioning – Confirm integrated system behavior under real-world conditions
• Production Testing for OEMs – Ensure every unit meets specifications before shipment

Key subsystems to focus on: 

• UPS and Battery Backup Systems – Runtime validation, transient response, and BMS functionality 
• Switchgear and Power Distribution – Failover logic and power quality under dynamic loads
• Backup Generators – Load simulation and response monitoring during commissioning 
• Energy Storage Systems – Charge/discharge cycles and safety interlocks

The Better Way 

DMC brings decades of experience testing DC power systems for the automotive and aerospace industries, where reliability is non-negotiable. We apply that expertise to data center DC and AC power infrastructure with automated test solutions that: 

• Execute custom or standard test scripts
• Control load banks to simulate real-world conditions
• Monitor power quality and transient response
• Log and report results for compliance and traceability

DMC excels at thinking outside the box. It’s what sets us apart. We don’t just deliver cookie-cutter solutions; we design and integrate unique systems tailored to your requirements and challenges. Whether you need a turnkey test station or a creative approach to integrate with existing equipment, we’ll find a way to make it work. 

Component-Level Testing 

Before you can trust the entire system, you need confidence in its building blocks. Component-level testing ensures that each UPS, battery module, switchgear panel, and generator meets its specifications under controlled conditions. This step verifies: 

• Electrical performance and safety compliance 
• Firmware and control logic functionality
• Proper response to simulated faults and load changes

Component testing is essential for quality assurance and regulatory compliance, but it’s only the first step. Even when every component passes, integration can introduce new failure modes. That’s why system-level testing is equally critical. 

System-Level Testing 

Component-level testing ensures each part works as intended. But data centers operate as complex systems, and failures often occur at the interfaces: 

• UPS and generators may not synchronize during transfer 
• Switchgear logic may falter under simultaneous load changes 
• Battery systems may behave unpredictably during extended outages

System-level testing replicates these scenarios before they happen in production, saving time, money, and reputation. 

Further Reading 

• Automated Testing of a Mobile Energy Storage System
• Smart Energy AMP Solution
• Battery Testing with Large Scale Distributed Platform
• DMC Joins Strategic Partnership with Battery Innovation Center

Let’s Start the Conversation 

Data center reliability starts with rigorous testing. If you’re asking: 

• Who’s doing this testing? 
• How are we testing? 
• Is there a better way? 

The answer is yes; there is a better way. Let’s talk about how DMC can help you validate every critical subsystem and the entire power system before it goes live. 

The post Data Center Construction: How Are You Testing Your Power Systems? appeared first on DMC, Inc..

At DMC, we believe that control-system modernization can often be the smarter, faster, and more cost-effective path, especially for complex, mission-critical test stands. In most cases, modernization deserves some more serious consideration. 

Why Modernize Instead of Replace? 

1. Preserve What Works, Upgrade What Matters

Most legacy test stands, like those used for aircraft engine components, feature robust mechanical and electrical assemblies that remain fully functional. The real bottleneck is usually outdated control consoles, operator interfaces, instrumentation, data storage, and software, which have all increased exponentially in capability and performance over the last several decades.

Meanwhile, mechanical systems haven’t changed much over the last few decades, so why replace something that isn’t broken? By focusing upgrades on the control architecture and instrumentation (software, electronics, & DAQ systems), you can: 

• Significantly reduce cost, downtime, and risk compared to full system replacement. 
• Meet modern requirements for cybersecurity, diagnostics, traceability, and user experience. 
• Avoid the complexity and uncertainty of integrating entirely new hardware into your workflow. 

2. Own Your Platform And Your Future

Modernizing with open, industry-standard platforms (like NI LabVIEW, Python, TestStand, VeriStand, PXI, cRIO, and cDAQ) means you own the software, hardware design, and architecture. This empowers your team to: 

• Expand and adapt the system as needs evolve. 
• Choose your support partners, whether DMC, your internal team, or another qualified supplier. 
• Avoid vendor lock-in and ensure long-term serviceability. 

3. Get Proven Results

DMC’s approach is grounded in a track record of successful modernization projects for commercial, military, & aerospace clients: 

• US Air Force Landing Gear Test Facility (LGTF): DMC replaced an aging control system on a one-of-a-kind aircraft tire dynamometer, delivering a modern, open-platform solution that extended the facility’s capabilities and lifespan. 
• Outboard Marine Engine Test Cells: DMC automated legacy test cells for a global engine manufacturer, improving data acquisition and keeping costs in check. 
• Commercial Vehicle Transmission Test Rigs: By refurbishing control systems and software while preserving mechanical infrastructure, the DMC team saved clients over $1M per rig compared to buying new. 

A Phased, Low-Risk Approach 

DMC recommends a structured, phased process for most test cell modernization projects. This approach ensures you only invest where it matters, with full transparency on costs and timelines. 

1. Assessment: Collaborate with the client, stakeholders, and end users to evaluate upgrade options and risks. 
2. Design: Develop detailed plans for the new instrumentation and control system. 
3. Deployment: Build, test, and roll out the upgrade, minimizing downtime. 
4. Futureproofing: Allow for optionally upgrading other necessary systems later, without overhauling the control system. 

Conclusion

For Aerospace and Defense organizations, modernizing test infrastructure isn’t just a budget-friendly alternative—it’s a strategic move that maximizes asset value, accelerates readiness, and supports long-term mission success. Before you sign off on a brand-new test rig, ask: What could you achieve by simply modernizing the brains of your existing system? 

The post Why Buy New? The Case for Modernizing Test Rigs in Aerospace & Defense appeared first on DMC, Inc..

This technical blog distills how and when to use FPGAs for custom measurements, the architectural patterns that actually work, and hard‑earned tips from DMC projects, plus links to DMC case studies and technical blogs you can reference as you architect your own system.

Why an FPGA for Measurement?

Determinism from microsecond to nanosecond scales
FPGA logic executes in hardware with clock‑accurate timing. On NI RIO targets, you can use single‑cycle timed loops (SCTLs) to run logic loops timed by clock signals that you specify. These loops have extremely low jitter, meaning that every iteration of the loop executes in the same amount of time. When you need very high confidence that control loops have a consistent time delta or that timestamps can be trusted, an FPGA may be the right tool.

Massive parallelism
Independent loops of logic on an FPGA execute in parallel. Unlike conventional CPUs, adding more loops to count edges, filter data, or implementing serial protocols won’t slow the other loops. This is ideal for multi‑sensor, mixed‑signal acquisition or protocol gateways.

Throughput without host bottlenecks
Stream continuous, high‑rate data using DMA FIFOs between FPGA and host, or bypass the host entirely with Peer‑to‑Peer (P2P) streaming between PXIe modules on the backplane. The FPGA can share data with oscilloscopes, waveform generators, vector signal analyzers, and more without burdening the host processor or memory.

Custom I/O and protocol timing
Implement custom digital front‑ends, encoders, counters, PWM, or proprietary serial timings that off‑the‑shelf DAQ devices don’t support. With CLIP and the IP Integration Node, you can also drop in HDL cores (VHDL/Verilog) or Xilinx IP where needed.

When to Choose an FPGA vs. PC or Real-Time (RT)?

Use this quick rule of thumb (derived from DMC best practices and NI documents):

• Choose FPGA when you require sub‑microsecond latency; hardware‑synchronous data paths; custom protocol waveforms; lossless streaming at hundreds of kS/s to GS/s; or multi‑loop parallel logic that must always meet timing.
• Choose RT (cRIO/PXI RT) when you need deterministic millisecond‑level control, supervisory logic, or file/logging tasks that coordinate with FPGA work. RT + FPGA is a common pairing.
• Choose PC when you need rich UIs, analytics, databases, or post‑processing, and timing isn’t safety‑critical. (Still pair with FPGA for preprocessing and rate reduction.)

DMC uses all three layers across industries (aerospace, electrification, advanced manufacturing), typically placing tight control and fast parallel logic on the FPGA, supervision and coordination on RT, and UX/data management on Windows. See our Real‑Time & FPGA overview and examples on DMC’s services page.

LabVIEW FPGA Essentials (what matters in practice)

Move data predictably:

Targets & clocks
Your LabVIEW project contains an FPGA target (cRIO chassis, FlexRIO, etc.) with base clocks (40 MHz onboard) and optional derived clocks. The top‑level clock governs logic outside SCTLs; SCTLs run in their selected clock domain. Use multiple clock domains to execute calculations at lower rates and fast I/O logic at higher rates.

DMA FIFOs
DMA FIFOs allow you to transfer data to and from the FPGA and host. The FIFO size can be scaled to avoid overflows. You can also create target‑scoped FIFOs to communicate between loops, but be sure to understand the different FIFO implementations.

Fixed‑point everywhere
Floating‑point math is expensive in FPGA fabric. Instead, you can do fixed‑point (FXP) math to be more hardware‑efficient. Controlled rounding and overflow modes and configurable word lengths & layouts allow you to plan for your specific algorithm. Prefer saturate where correctness is more important than speed, and wrap to optimize for resource usage. NI’s tables and guides are gold when sizing numeric types.

Bring your own HDL when needed
With CLIP (component‑level IP) or the IP Integration Node, you can insert vendor IP, legacy VHDL, or Xilinx IP cores into your own code to accelerate development.

Patterns DMC Reuses for High-Performance Measures

1. Deterministic data capture and stream
   Use the FPGA to capture signal edges with nanosecond resolution, decimate and filter the data on FPGA, stream features to RT/PC via DMA, and use the host system for logging, visualization, and analytics. We’ve applied this multi‑layered FPGA/RT/PC architecture on aerospace and defense systems with >500 channels.
2. Custom waveform synthesis at GS/s
   With FlexRIO adapter modules, we’ve generated parameterized waveforms (delay/hold/ramp) at 1.25 GS/s using an adapter like the Active Technologies AT‑1212. Generating the waveforms on FPGA allows nanosecond‑level timing, great for optical/LIDAR, RF, and pulsed power.
3. Frequency‑domain triggers & inline RF analysis
   Use P2P to stream digitizer data straight into an FPGA for windowing/FFT/mask comparison, then control backplane trigger lines to capture only events of interest. This eliminates host copies and makes “impossible” real‑time analyses practical.
4. High‑speed protocol emulation & HIL
   The FPGA implements line‑speed channel models and packet timing, while PXI instruments handle I/O—use DMA for logging and P2P for cross‑module data paths. We’ve used this architecture in demanding hardware‑in‑the‑loop modem testing.

A Pragmatic LabVIEW FPGA Architecture

Keep the FPGA’s job small
Do the minimum required at hardware speed: time‑critical I/O, data reduction, protection, and lossless streaming. Push everything else to RT/PC. (This guideline is ubiquitous in DMC training decks.)

Use SCTLs wisely
SCTLs reduce resources and latency but increase timing pressure. Pipeline long combinatorial paths, separate fast and slow clocks, and avoid SCTL‑incompatible nodes (e.g., certain I/O or waiting functions).

Engineer your clocks
Start with the 40 MHz onboard clock and derive others only as needed. On FlexRIO, additional base clocks (100 MHz/200 MHz) and DRAM clocks are available; match clocking to I/O and algorithm needs.

Get data off the FPGA early
Choose target‑scoped FIFOs for on‑fabric communication and DMA FIFOs for host transfer. If you’re in a PXI(e) system and need device‑to‑device throughput or deterministic fan‑outs, configure P2P streams with NI‑P2P.

Choose numeric types deliberately
Pre‑size FXP to prevent overflow and use truncate where quantization error is tolerable.

Development & Debug Workflow that Saves Weeks

Simulate before you compile
FPGA builds can take minutes to hours. Use Simulated I/O and the FPGA Desktop Execution Node to build testbenches with simulated time, probe internal signals, and validate algorithms long before you commit to a hardware compile.

Layered testing
It’s a best practice to take a unit → component → system verification approach. Simulate units without I/O; component‑test clocked processes; then system‑test with real I/O or emulated streams.

Compile strategy
Use the FPGA Compile Cloud Service or a compile farm to parallelize big builds and keep engineers moving. NI’s developer center outlines your options.

Hardware Selection Notes

• cRIO: Rugged, modular C‑Series I/O; great for embedded measurements and deterministic control. Default 40 MHz FPGA clock; derive carrier clocks as needed.
• FlexRIO: PXI(e) FPGA with adapter modules for GS/s converters, custom front‑ends, and P2P; multiple base clocks; DRAM; ideal for inline DSP and RF/fast transients.
• R Series / Multifunction RIO: General‑purpose FPGA with direct DIO/AIO; useful when you need custom timing on classic DAQ channels.
• Other Platforms: If nothing above hits the mark, DMC can leverage our Embedded Services Team to develop a truly custom solution: FPGA Programming

If you’re unsure, DMC often starts with a short discovery mapping I/O timing, throughput, and latency to the simplest platform that meets the spec, escalating to FlexRIO only when rates, bandwidth, or P2P drive the need.

Real-World Examples & Further Reading

Top 5 FPGA-Related DMC Case Studies

Top 5 FPGA-Related DMC Blogs

1. NI LabVIEW Part 1: Building Distributed and Synchronized FPGA Applications
   Explains synchronization techniques for multiple FPGA chassis using NI 9469 modules.
2. NI LabVIEW Part 2: Synchronized Data Acquisition across Distributed FPGA Chassis
   Discusses DMA FIFO strategies for transferring data between FPGA and RT targets in multi-chassis systems.
3. RT-301: Capabilities of Distributed LabVIEW Real-Time
   The major benefits of running a Real-Time system are determinism and robust operation.
4. FPGA Programming Overview
   A service-focused blog detailing FPGA programming capabilities, including Xilinx, Intel, and LabVIEW FPGA platforms.
5. Troubleshooting NTP with NI Hardware
   While not purely FPGA, it’s relevant for time synchronization in FPGA-based DAQ systems.

A Starter Checklist for your FPGA Project

1. Quantify timing: Required max latency, jitter, and timestamp resolution. If < 10 µs, you’re likely in FPGA territory.
2. Estimate throughput: Peak and sustained rates; raw vs. reduced features; choose DMA vs. P2P accordingly.
3. Partition the system: What must run in SCTLs? What can run in a slower clock? What can RT/PC do?
4. Pick numeric formats: Fixed‑point widths, rounding/overflow policies; verify with simulation.
5. Plan testbenches: Use Simulation (Simulated I/O) and the Desktop Execution Node before hardware compiles.
6. Design streams & buffers: Size FIFOs to cover bursts of data and verify that underruns or overflows can’t occur in worst‑case scenarios.

How DMC Can Help

DMC has delivered deterministic, high‑throughput measurement systems across avionics, RF, electrification, and advanced manufacturing—often blending FPGA inline processing with RT coordination and PC‑level analytics and UX. Our team includes NI Certified LabVIEW Architects and deep FlexRIO/cRIO experience. Explore our Real‑Time/FPGA services and reach out—we’ll help right‑size your architecture and accelerate your first build.

The post Using FPGAs for Custom High-Performance Measurements (Intro to LabVIEW FPGA) appeared first on DMC, Inc..

One of these issues is that many organizations struggle to strike the right balance between internal ownership and external execution when it comes to developing and sourcing their test systems. Some try to do everything in-house and run into bandwidth and/or capability issues. Others outsource too much, losing product-specific expertise, struggling with decision making and alignment of internal stakeholders, and lacking any cohesive testing strategy. Perhaps worst of all are the customers we have worked with long enough to see them periodically cycling between these two ends of the spectrum, as they overcorrect issues observed during their latest attempts at sourcing test systems.  

At DMC, we’ve seen the most successful clients follow a hybrid model—one that empowers internal test engineers to lead strategically while leveraging external experts for test system execution and technical innovation. 

The Pitfalls of Going It Alone

Relying solely on internal teams to ‘do it all by themselves’ can lead to: 

• Resource bottlenecks: Internal engineers often juggle multiple priorities and lack time for deep system development. 
• Limited exposure: In-house teams may not be familiar with the latest tools, platforms, or test strategies across industries. 
• Missed opportunities: Without external input, test systems may be overbuilt or misaligned with budget and timeline constraints. 
• Over- and under-staffing: Depending on how often your business needs new or updated test systems, you are either paying for engineers to sit on the bench or constantly resource constrained. 
• Getting lost in the weeds: Engineers may place too much focus on technologies and software architectures rather than testing process effectiveness, efficiency, and overall product quality. 

Misdirected Internal Engineers: A Hidden Risk

On the flip side, some organizations bring in external partners to deliver their test systems and fail to prepare and engage their internal test engineers effectively. Without preparing your internal test engineers, they may act as ‘internal competition’ to the external team. Some clients believe they don’t need any internal test engineer involvement once they make the decision to use an outside partner. 

These mistakes often result in: 

• Missing, incomplete, or total lack of requirements and test specifications 
• Poor stakeholder communication and misalignment on goals 
• Trouble making engineering and project trade-offs quickly 
• Lack of ownership for test system validation and deployment 
• Internal test engineers feeling “left out” of the process and marginalized 

Best Practice: Strategic Internal Ownership + Expert External Execution

The most effective model we’ve seen used by customers is a hybrid model that fits somewhere in between the two extremes, with internal and external resources playing roles based on their strengths and in constant communication. 

Internal Test Engineering Team Owns: 

• Budget and scheduling allocation and processes 
• Overall stakeholder alignment, from the beginning to the end of the project 
• Understanding the critical product functions and test specifications 
• Providing subject matter expertise for any industry or customer-specific technologies required, or acting as an intermediary with internal team members 
• Producing clear requirements and definitions to the external team, ensuring expectations are realistic, testable, and traceable 
• Providing project management during the execution phase 
• Leadership of test system validation and acceptance testing, to ensure the delivered system meets performance, quality, and usability goals 
• Long-term ownership of the delivered test system, calibration, maintenance, overall testing process, and data analysis and monitoring 

External Test System Integration Partners Bring: 

• Consultative insight into meeting test goals within budget and time constraints while maintaining a consistent overall testing strategy 
• Knowledge of the latest best practices across many industries and lessons learned from the execution of dozens of test and measurement projects per year 
• Up-to-date technical know-how and subject matter expertise in platforms like NI LabVIEW, TestStand, SystemLink, and cloud-enabled test environments 
• Scalable system architectures with support for global deployment, multi-channel systems, and integration with any laboratory or factory-floor systems 
• Efficient execution of test system design, build, and deployment 
• Proper software development practices, including testing, integration, code reviews, revision control, documentation, and release 
• Full hardware system management, including design, customer reviews, drawing revision control, design release processes, fabrication, system startup and testing, documentation, and subcontractor and supplier oversight 
• High-level troubleshooting and maintenance assistance after system startup 

Case Study Examples

DMC’s recent work on ECU (electronic control module) and BMS (battery management system) EOL (end-of-line) test systems illustrate this model well. The customer’s internal test engineering teams defined the performance goals and test specifications and frequently consulted with DMC on a few critical requirements to ensure they could fit within their tight budget and schedule demands. From there, DMC executed the system design, software development, test stand build, and validation. The result was delivery and handoff of a robust, scalable solution that met quality and production needs without overburdening internal resources. 

• Bed of Nails Battery Management System PCB Test Station 
• Functional End of Line Test System for Automotive ECUs 

Conclusion

The key to success isn’t choosing between internal and external routes to test system delivery—it’s knowing how to combine them effectively. Organizations can build smarter, faster, and more cost-effective test systems by: (A) empowering their internal test engineers to manage and lead strategically and (B) partnering with experienced external teams like DMC for execution.

We Can Help

If you’re looking for consulting or support as you navigate the complexities of effectively outsourcing your test system development, give us a call!

The post Bridging Expertise: How to Maximize Value from External Test & Measurement Partners While Empowering Your Internal Engineering Team appeared first on DMC, Inc..

Here are some of our favorite insider strategies for maximizing the benefits of VeriStand:

1. Use Built-In CAN Control to Avoid Custom Devices

If your hardware sports a CAN interface (like so many different battery cyclers), you can skip writing a custom device entirely. VeriStand’s built-in CAN functionality is often sufficient for direct control, saving hours of development time and reducing long-term maintenance. We use this so often that you can simply check out any VeriStand case study we’ve made.

This trick came up quickly while quoting a battery test stand project where we immediately realized we could control the cycler natively—no LabVIEW or custom device needed.

2. Delete the VeriStand Cache to Fix Project Crashes

VeriStand occasionally crashes when loading large or complex projects. One fix that worked for us: delete the .cache folder inside the project directory. This resolved persistent load failures and is now part of our troubleshooting checklist.

We discovered this during SAT preparation for the Power HIL Test Stand for an Autonomous Air Vehicle. This one is a lifesaver when you’re under deadline pressure.

3. Real-Time Sequences Run Independently of the PC

Once deployed, VeriStand real-time sequences continue running even if the host PC disconnects. This makes VeriStand ideal for low-cost autonomous test stands—just make sure your sequences don’t rely on dynamic updates from the PC. See one of our case studies using this trick.

We confirmed this with NI Tech Support and now use it to run long-duration tests without worrying about PC uptime.

4. Custom Device Development for HMI Integration

Need to push data from VeriStand to an external HMI? Skip the PC and consider using the Ethernet/IP or Instrument Add-on custom device. This allows you to build flexible VeriStand UIs without relying on LabVIEW, which is great for clients who want maintainability and are sensitive to licensing costs.

We used this approach in a project with an energy storage startup company to integrate a touchscreen HMI with a fuel cell test stand, while keeping their replication costs minimal.

5. Python-Based Real-Time Sequences

VeriStand’s Stimulus Profile Editor supports importing Python-based sequences. This opens the door to more flexible scripting, especially for teams more comfortable with Python than NI’s native tools.

One of our engineers once documented this in a ‘what if’ brainstorming list, and it’s now our go-to method for complex stimulus profiles.

6. Simulating Battery Behavior with Custom Models

In a recent BMS test stand, we built a custom electric circuit model in VeriStand to simulate battery state-of-charge, voltage, and temperature responses. This allowed the client to test flight termination scenarios and temperature excursions without real hardware. See our case study.

This technique was key to validating edge cases that would be risky or impossible to test with live batteries.

7. Tiered Architecture Strategy: VeriStand + TestStand + LabVIEW

When designing battery test systems, we often present clients with three architecture tiers:

• Tier 1: Full NI stack (VeriStand + TestStand + LabVIEW)
• Tier 2: Hybrid solutions using VeriStand with custom scripting
• Tier 3: Fully custom DMC-developed RT applications

This helps clients balance flexibility, cost, and maintainability.

We’ve used this framework to guide architecture decisions for projects ranging from R&D benches to production test systems.

8. Use Aliases to Future-Proof Your System Definition

Assigning an alias to every element in your System Definition File (SDF) helps ensure that screens and sequences continue to work even when variables are renamed. Instead of renaming in the SDF and hunting down every reference, you simply rename the variable and remap the alias.

This trick has saved us countless hours during refactoring and is especially useful in large systems with many dependencies.

9. Alarm Thresholds Are Inclusive—Watch Your Limits

VeriStand alarm thresholds are inclusive, which can trip you up if you’re expecting binary behavior. For example, if you want an alarm to trigger only when a value hits 1, set the high limit to 0.5—not 1. Otherwise, the alarm may not behave as expected.

This one definitely caught us off guard early on. It’s subtle, but important for getting clean alarm logic.

10. The Best Tips Come from the Field— Reasons to Call in an Expert

These tips aren’t in the manual—and that’s the point. They come from real projects, real problems, and real solutions. Every tip in this list came from real DMC projects—none of them are pulled from the web or manuals. They’re the result of solving problems under pressure, collaborating across teams, and refining our approach over time.

Final Thoughts

If you’re building a real-time test system with VeriStand, we hope these tricks help you go faster, debug smarter, and deliver better results. If you’re an engineer with more VeriStand wisdom to share, reach out! We’d love to include your insights in a future update. If you have never used VeriStand, but are considering it, or are already using it and want expert help, give us a call or send us an email. You’ll speak right to an engineer who’s been there and feels your pain, not a salesperson.

The post Developing Real-Time Test Applications with NI VeriStand: Tips and Tricks appeared first on DMC, Inc..

Electronic Control Units (ECUs) are the digital brains behind nearly every system in modern vehicles, from classic engines and transmissions to battery management systems, inverters, and DC-DC converters. As vehicles become more connected and software-driven, and move toward new concepts like zonal controllers, the need for secure, efficient, and flexible ECU programming in production environments has never been greater.

Manufacturers face mounting challenges like exponential growth in calibration parameters, evolving cybersecurity requirements, and the increasing size and complexity of ECU firmware. Throw in the need to program ECUs for multiple OEMs and specific end-users across multiple manufacturing lines inside facilities distributed around the globe, and the ‘simple’ process of flashing an ECU can quickly become a tangled mess. 

Industry Trends: Why Clients Need to Stay Ahead of Cybersecurity and Complexity Challenges 

Modern ECUs are increasingly targeted by cyberattacks, and the size and sophistication of ECU firmware is growing rapidly. Manufacturers must stay ahead of cybersecurity and complexity challenges to ensure robust, future-ready ECU software management. DMC’s Production ECU Software Download Station provides a turnkey platform that addresses these needs, while offering the flexibility to customize the system to unique client requirements. 

The Challenge: Complexity, Security, and Cycle Time

Traditionally, manufacturers have adapted existing assembly line stations, often at End-of-Line (EOL) test, to handle ECU programming. However, this approach is fraught with issues: 

• Flashing software is slow and error-prone if not done correctly. 
• Modern ECUs require multiple software components like bootloaders, memory configuration, customer-specific calibrations, and evolving security libraries. 
• Cybersecurity requirements are increasing. ECUs are now targets for hackers seeking to exploit vulnerabilities in vehicle networks, firmware, and diagnostic ports. The ISO 21434 standard and SAE guidelines now mandate robust cybersecurity engineering for automotive systems. 
• Cycle (TAKT) time is impacted. Adding ECU software download steps to critical stations cuts into overall production efficiency (OEE). 

The DMC Solution: A Digital Assembly Line for ECU Programming 

DMC’s Production ECU Software Download Station is designed to address these challenges head-on. Built on the DMC Cortex Framework and leveraging robust NI cDAQ hardware, this solution offers: 

• Object-Oriented LabVIEW-based software for flexible and scalable automation. 
• Support for NI XNET, Vector and 3rd party interfaces for CAN, LIN, and Automotive Ethernet communications. 
• NI TestStand integration for easy download sequence definition and customization. 
• Ready for Hi-Mix Applications. This solution easily supports multiple ECU variants and a high mix of models and end-product configurations. 
• Compact station design capable of programming 4, 8, or more ECUs asynchronously in parallel, reducing floorspace requirements and saving cycle time for capital-intensive assembly and test processes. 
• Assembly Line-Ready. Most typical machine builder/PLC interfaces (Modbus, EthernetIP, Profinet, etc.) are supported for connection to assembly line tooling and systems. 

Key Features and Specifications

Real-World Success: Case Studies 

1. Automotive Flashing Station for End-of-Line Test
   DMC delivered a robust 4-UP ECU flashing solution for an automotive client’s assembly line using the NI toolchain to eliminate ongoing licensing costs. The delivered system enabled secure, efficient, and parallel programming of 4x ECUs with the latest firmware and calibrations. The DMC system increased data and process organization thereby reducing the time needed for the Client’s engineering teams to release updates to their assembly lines and eliminated opportunities for misconfiguration of the system. 
   Read the full case study: Test Stand Automative Flashing Station 
   
2. 8-Up ECU Flashing Station 
   For another client, DMC implemented an ECU flashing station capable of programming up to eight ECUs simultaneously, using the Vector toolchain, dramatically improving throughput and reducing cycle time. Use of the Vector toolchain reduced flash package development and deployment time for the client’s controls software team. 
   Read the full case study: 8-Up ECU Flashing Station 

Download the Full Solution Brief

Download DMC’s ECU Production Software Download Station solution brief.

Why Work With DMC?

DMC is a leading systems integrator with decades of experience in test system automation and hardware/software integration for production lines and R&D labs. With a nationwide presence, worldwide delivery capability, and stable long-term support, DMC delivers solutions that are both robust and adaptable.

“They truly took ownership and pride in their end of the project, ultimately resulting in an outstanding working relationship and final product. We will continue to work with and recommend DMC for future projects.” 
— Jeff Wasil, Associate Engineer at BRP 

Beyond Flashing: Embedded Firmware & Application Development

DMC’s team doesn’t just build test stations—we also develop embedded firmware for ECUs, ensuring seamless integration and optimal performance. Learn more about our capabilities: 

Firmware Programming 

For clients managing large fleets of ECU download stations, server- and cloud-based applications for station management and data collection are a natural extension of our platform. These additional solutions can help centralize control and security, streamline system updates, and provide powerful analytics and dashboards for production-ready operations. 

Explore our Application Development services. 

Need Help or Have Questions? 

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