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Reliability Engineering Services

Solve your toughest product reliability challenges

Predict and Prevent Reliability Challenges Before They Happen

Ansys Reliability Engineering Services (RES) is the leader in delivering comprehensive reliability solutions to the electronics industry. Ansys RES leverages a team of reliability experts within a 20,000 sq. ft. laboratory & test facility to accurately predict the robustness of a device, investigate failures through physical testing, determine potential design changes through simulation and modeling and more. Ansys RES routinely helps clients optimize product reliability and accelerate time to market.

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    One-on-one consultations and support
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    Customized Solutions
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    Comprehensive & actionable recommendations
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    Time-sensitive reliability improvements

Featured Lab Capabilities

Ansys’ multi-million dollar test lab facility features 20,000 square feet of lab and test space, including 25 environmental chambers, component and sub-system testing and a full-service material characterization and failure analysis lab.

Our team of RES experts have decades of experience to get to the root of the problem, mitigate failure risks and devise practical solutions—all within your timeline and cost constraints. 

  • X-Ray
  • Digital Image Correlation (DIC)
  • Optical / Acoustic Microscopy
  • Mechanical Shock / Drop testing
  • Vibration Testing
  • Temperature Cycling
  • Elevated Humidity Testing
  • Mechanical Testing
  • Custom Test Chambers & Fixtures
  • Battery Quality Assessment
  • Scanning Electronic Microscopy (SEM)
  • Energy Dispersive Spectroscopy (EDS)
  • Sample Preparation
  • Contamination Analysis

Reliability Engineering Services

Design Review

Design reviews are critical steps in building an effective product. However, for most organizations, this process isn’t easy. Team members are often reluctant to criticize their colleagues’ ideas, and ODM vendors can be unwilling to share design information. Overall, organizations often have a hard time completing an effective design review without sacrificing time, resources and funds.

Ansys eases the burden of this process by delivering design reviews monitored by neutral, third-party subject matter experts. We specialize in a reliability physics-based approach to design review and optimization, providing the input you need to develop products that meet customer expectations — on time and within budget.

Our experts have designed, manufactured, tested and provided root cause analysis support for electronic products and systems for over 30 years. This breadth of experience enables us to rapidly identify issues and provide you with specific and actionable feedback.

We offer unrivaled knowledge in a range of products, systems and applications, including:

  • Semiconductors.
  • Power and analog design.
  • Electronics manufacturing.
  • Batteries.
  • Displays.
  • Corrosion protection.
  • Housing and enclosures.
  • Cabling and connectors.
  • Pneumatics and fluid flow.
  • Mechatronics.

Our evaluations are supported by industry best practices, fundamental manufacturing knowledge, simulation and modeling, and reliability physics analysis.

With Ansys’ design review services, you can create a product with fewer design revisions, resulting in faster time to market with less risk.

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Simulation and Modeling

To minimize testing and warranty costs and ensure faster time to market, you should know if your product will work in your application environment before you build it. Testing design ideas virtually, using simulation and modeling, is the most efficient way to reduce the risk of costly surprises in the product development and deployment lifecycle. The key to accurate simulation and modeling is a strong grasp of the physics and material properties that govern the behavior of the model. Without that, simulation and modeling can lead to a false sense of security and unexpected failures during qualification testing or field use.

Ansys combines industry-leading simulation software, expertise in reliability physics, and physical lab and test facilities to ensure timely and accurate simulations of product reliability. Our simulation and modeling staff are experts in reliability physics who work closely with you to understand your product’s use environment and design details to ensure they incorporate relevant features into the simulation. The time spent planning the simulation minimizes model build times and reduces the risk of inaccurate simulation results.

Ansys is the only CAE software company to own physical lab and test facilities, which can help ensure the accuracy and applicability of simulation results. While data sheets and material databases can provide general material information, the properties of the specific materials or components of your design may differ from those standards. Equipped with extensive materials experience, Ansys experts can help you identify the material properties that may vary from data sheet values, then use our lab and test facility to measure those properties and ensure the simulation is based on sound inputs.

Our lab and test facilities also allow for robust validation of simulation results. No matter how detailed, all simulations are simply estimates of how the product will behave in the real world. Before using a simulation to make important design decisions, it is useful to validate or tune the simulation to ensure the simulation is sufficiently close to reality. Using our lab and test facility, we can test full products or product subsystems to ensure that the accuracy of simulations is sufficient prior to use for key design iterations and decisions.

Ansys specializes in simulation and modeling focused on assessing and improving the reliability of electronics. Whether your design includes complex material or structural behavior and interactions; time-varying mechanical, electrical and thermal loads; or innovative thermal management solutions, the Ansys team has the tools, expertise and infrastructure to tackle your most demanding product reliability simulations.

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Supplier Assessment

Electronic systems can contain thousands of parts made by a host of different suppliers. To produce the most effective and reliable product, it’s critical to choose suppliers whose components will optimize your product’s performance and reliability. However, organizations often don’t have the time, resources or expertise to thoroughly vet every potential supplier.

At Ansys, we conduct supplier assessments on your behalf, so you can rest assured that you are working with the right supplier. We draw on decades of experience and thousands of design reviews to provide comprehensive technical and quality assessments, so you can choose the supplier that will help you achieve robust product performance.

We evaluate a broad range of technologies, including:

  • Materials.
  • Components.
  • Circuit boards.
  • Electronics.
  • Batteries.
  • Displays.
  • Housings.
  • Motors.

Whether you’re evaluating contract manufacturers, ODMs or off-the-shelf technology, we work to identify the best supplier for your organization. Following the assessment, we provide you with the selection criteria and prepare you to independently evaluate suppliers in the future.

The right supplier can lead to lower production costs, less risk and improved products. We can help you make the best selection for your company.

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Accelerated Life Testing

Before your company launches a product, you have to think of everything: What would happen to your company’s reputation if your product underperformed? If your product failed, could it cause physical harm?

Product reliability is essential for success, and Accelerated Life Testing makes it possible to answer these questions before your launch. This process accelerates testing by increasing stress on a device to induce and accumulate damage faster than in the field. From there, you can better understand the cause of the failure. Ultimately, you can accurately simulate the extreme circumstances a device may experience in a real-world environment, leading to improved product performance, faster time to market and reduced warranty costs.

At Ansys, we leverage our relationships with over 1,000 companies across multiple electronics markets to expose design weaknesses and identify solutions to those inefficiencies. Our expert reliability team determines which stresses and tests to apply, how to set appropriate test parameters, and how to interpret the results. This leads to efficient, accurate and streamlined remedies for any design flaws — and improved product performance for your company.

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Failure Analysis

When your product fails, you need to know why and understand how to fix it. However, with so many parts produced by so many manufacturers, it’s not easy to narrow down the point of failure and its root cause. If your company doesn’t identify and address those failures, you could face increased testing costs, a delay in time to market and increased warranty costs.

A thorough failure analysis is a critical step to recover from test and field failures; it also teaches you how to prevent similar failures in future designs. At Ansys, our primary goals in failure analysis are to identify the root cause of failure and, unlike other failure analysis organizations, develop mitigation strategies to prevent the failures from recurring.

Ansys approaches each failure analysis from a reliability physics perspective, seeking to understand the physical, electrical, mechanical, materials, physics and chemistry issues that may be contributing to failure. After thousands of failure analyses for customers in nearly all major industries, the Ansys team has the unique ability to quickly identify the potential root causes of failure and understand how to eliminate them.

For your company, that means less retesting, faster time to market and swift resolution of reliability issues in the field before they drive significant warranty costs or customer dissatisfaction.

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Integrated Circuit Reliability

Integrated circuit (IC) components are part of nearly every major electronics application. However, up to this point, most reliability assessments focused on meeting the demand of consumer applications that last an average of five years. Today, many emerging market segments require reliable operations for 10 to 15 years, even in severe environments. Robust prediction of IC life in modern, high-reliability applications requires a different approach.

With a foundation in reliability and semiconductor physics, the Ansys team uses simulation, testing and teardown analysis to define failure risk in specific applications and identify the key drivers of IC reliability. Whether you are trying to reduce component integration risk in a new application or trying to solve an IC reliability challenge in a severe environment, our experts have the experience and resources to help.

Traditional simulation and modeling techniques for ICs require extensive design, manufacturing and test information that is not typically available to IC integrators and product designers. Our approach brings simulation and modeling within reach by using data they can typically acquire. Based on proven methods, our approach uses information about the technology node and functional blocks within the IC to predict susceptibility to hot carrier injection, negative bias temperature instability, time-dependent dielectric breakdown and other common IC failure mechanisms. We can simulate the reliability of ICs in application-specific environments and help designers mitigate IC reliability concerns early in the development process.

Ansys also designs and conducts environmental testing of ICs under load and can evaluate bit errors and other signs of wear through in situ monitoring and failure analysis, as appropriate.

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Battery Reliability

Wearables, smart phones, electronic vehicles and Internet of Things devices all depend on one thing: batteries.

As your company and its products increasingly rely on battery power, it’s critical that you consider battery safety, reliability and performance. Batteries can be highly reactive and susceptible to thermal runaway events or even catastrophic failures. Faulty batteries can be costly, pose physical danger to users and risk your company’s reputation. Determining if your approach to integrating batteries into your product is safe and reliable requires a thorough understanding of the chemistry and failure modes in batteries, and an evaluation of which battery technology is ideal for your product.

Proper qualification of batteries in a new application requires attention to the design, manufacturing, testing, storage and transportation of your product. The Ansys team brings together battery design and manufacturing experts with teardown and electrical testing capabilities to ensure the reliability and safety of your product at all phases of its lifecycle.

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Education and Training

Electronics technologies and their performance requirements are changing every day. New materials, new manufacturing methods, new component technologies and increasingly harsh use environments present significant challenges for designers. To keep up and continue providing your customers with advanced, reliable products, your company must stay up to date with emerging technologies and the impact they can have on the reliability of your products.

Ansys experts have developed and delivered thousands of courses in the field of electronics reliability and reliability physics for engineering, management and executive audiences. We can design courses to address your specific needs and provide you with information you can use immediately to address product reliability concerns.

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Material Characterization

One of the biggest challenges standing in the way of pervasive simulation across all industries is the lack of shared data between supplier and customer. Often, data sheets provided by suppliers do not contain critical information needed by the engineer or designer, such as material properties that are necessary for accurate model inputs. Even if the supplier has the necessary information, intellectual property rights concerns can often prevent a full and robust data exchange up and down the supply chain. This lack of information stifles the design and simulation process and causes misunderstandings that can result in unnecessary delays or significant warranty claims.

Ansys offers materials characterization services that provide solutions for missing component data. This service includes:

  • Electrical characterization
  • Mechanical characterization
  • Reliability characterization

Our electrical characterization process provides important parametric information about electronic components and printed circuit boards (PCBs). This capability includes basic information, such as VI curves and timing, to more complex behaviors, such as electromagnetic radiation and high frequency impedance.

Our mechanical characterization process accurately captures the necessary geometry and material properties to perform robust simulation of electronic packages, assemblies and entire systems. The Ansys team specializes in precise part deconstruction including 3D X-ray, digital image correlation (DIC) and decapsulation as well as temperature-dependent characterization of both on-board (i.e., underfill) and off-board (i.e., glass-filled housing) materials.

Our reliability characterization process utilizes accelerated life testing (ALT) to analyze how a productor component will function under stressors i.e., temperature changes, shocks or vibrations) at a much faster rate than in the field. Our work provides customer with data to perform powerful post-processing life predictions, including parametric shifts in integrated circuits (i.e., memory, CPU, ASIC, etc.), fretting behavior of connectors and fatigue/creep parameters of adhesives.

Important aspects of Ansys reliability engineering services (RES) material characterization:

  • Our simulation experts know exactly which data needs to be extracted and select the best form for simulation.
  • We are directly linked to Ansys Granta MI, enabling you to maximize your ROI by empowering your colleagues with unlimited data access.

At Ansys, we are committed to offering a RES suite dedicated to providing our customers with the tools needed for improved product performance, superior product design and faster time to market.

Test Validation

Simulation is increasingly viewed as the most powerful tool in the new product introduction (NPI) process. It has the potential to accelerate time to market, reduce bill of material (BOM) costs and successfully implement designs that bypass the competition.

Enterprise organizations must have confidence in simulation results to reach this best-in-class workflow. Confidence has traditionally been built up over time through direct experience with simulation tools and correlation with field performance. However, most companies do not have the luxury of changing their internal processes, training large numbers of users, paying for expensive software and then waiting two to five years to reap the benefits.

To help accelerate simulation-driven workflows, Ansys reliability engineering services (RES) now offers test validation to its customers. Test validation provides physical testing services to validate simulation results and accelerate adoption. Test validation is especially powerful for executives and managers that have a vision but struggle to convince engineers on the ground to trust simulation outputs.

Ansys test validation services include:

  • Validation of electrical simulations
  • Validation of thermal/mechanical simulations
  • Validation of reliability simulations

A variety of electrical parameters outputted from simulations can be validated utilizing Ansys RES’ physical laboratory. These include DC values (voltage, current, power), AC values (from kHz to GHz), electrically-induced physical damage — including electrical overstress (EOS) and electrostatic discharge (ESD) — and electrical fields, such as electromagnetic interference (EMI).

Our ability to validate thermal/mechanical simulations is based on a wide range of lab equipment calibrated to NIST standards. This equipment includes thermocouples, infrared cameras, digital image correlation (DIC), accelerometers and strain gauges.

Validation of reliability simulations utilizes our extensive accelerated and environmental testing capabilities. This includes high temperature operating life (for electromigration prediction), temperature cycling (for solder fatigue), temperature/humidity (THB) and highly accelerated stress testing (HAST) for corrosion prediction, random and sinusoidal vibration, mechanical shock and drop testing.

Ansys RES test validation is unique and powerful because:

  • Our simulation experts know exactly how to validate a wide range of simulation results and outcomes.
  • If results from a test validation do not match the output from simulation, we can leverage the results from test validation to quickly and decisively identify how to improve your pre- and post-processing to get accurate results every time.

At Ansys, we are committed to offering a RES suite dedicated to providing our customers with the tools needed for improved product performance, superior product design and faster time to market.

See What Ansys Can Do For You

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