How We Test for 24/7 Reliability in Mission-Critical Systems

Unlike consumer systems that can afford downtime or regular reboots, mission-critical applications demand:

• Continuous uptime
• Predictable performance under sustained load
• Tolerance to harsh environmental conditions
• Resistance to component fatigue or failure

1. Burn-In Testing (Continuous Runtime Validation)

Each system undergoes a burn-in test — typically between 24 and 72 hours — where the machine runs at full load to reveal early-life failures. This helps identify issues such as:

• Component instability under load
• Overheating or inadequate thermal management
• Power supply issues
• BIOS misconfigurations

We use diagnostic and stress-testing software to simulate real-world workloads and continuously monitor temperatures, voltages, and fan speeds (where applicable).

2. Thermal Testing

Heat is the enemy of long-term system health. We test for thermal performance under:

• High ambient temperatures, using controlled thermal chambers where required
• Fanless cooling scenarios, checking that passive cooling solutions are effective
• Extended load, ensuring no thermal throttling or overheating occurs during long periods of use

We verify that each system maintains optimal internal temperatures to avoid heat-related degradation over time.

3. Vibration and Shock Testing (When Required)

For systems destined for use in vehicles, rail, or manufacturing environments, we perform vibration and shock tests to simulate real-world movement and impact.

This ensures that internal components — especially SSDs, RAM, and cabling — remain secure and operational even in harsh, dynamic conditions.

4. Power Cycling and Cold Boot Testing

We validate that the system can:

• Reboot cleanly under a variety of conditions
• Handle power loss without OS corruption
• Boot reliably from cold, repeatedly

This step is crucial for systems that may experience scheduled or unscheduled reboots in the field.

5. Long-Term Component Validation

Where possible, we select components rated for extended use, including:

• Industrial-grade SSDs and RAM
• Capacitors rated for long MTBF
• Wide-temperature-range components

We also track and verify manufacturer lifecycles to avoid obsolescence or support issues during long deployments.

• A railway control system may need EN50155-compliant testing, including wide temperature operation and vibration resistance.
• An edge AI device may need to demonstrate stable GPU acceleration under 100% sustained load.
• A medical imaging system may require high-resolution display testing, low-noise operation, and strict EMC conformity.
• A military-grade system may require MIL-STD-810 testing for shock, vibration, humidity, and altitude.
• A factory-floor automation controller may need to operate within an enclosed cabinet in a dusty, high-temperature environment — tested accordingly with fanless cooling and IP-rated enclosures.
• A marine navigation PC may require salt fog resistance, corrosion protection, and low power draw to suit onboard power systems.