When evaluating a new assembly application, many engineers know they should evaluate prototypes, but aren’t always sure what that process actually looks like.
What will be done with the parts?
How many samples are needed?
What information should be provided?
What do you get back at the end?
At Orbitform, our Solutions Lab is designed to help manufacturers answer these questions before committing to equipment. Lab testing for assembly processes helps engineers validate design, tooling, and performance before production. Through lab testing and process development, we work with your parts, requirements, and design to determine what process will work and what won’t.
Understanding how this process works can help you move faster, avoid redesigns, and make more confident decisions.
Why Manufacturers Use Lab Development
Most customers don’t send parts just to “see what happens.” There’s usually a specific question they’re trying to answer:
Which assembly process should we use?
Will our design meet torque or retention requirements?
Do we need to adjust rivet size, geometry, or material?
What tooling is required to form this part properly?
In many cases, it’s about alignment between the part design, functional requirements, and assembly process.
What Actually Happens During Lab Development
From the outside, lab development can seem like a black box. In reality, it’s a structured process focused on solving a specific problem.
At Orbitform, lab development typically includes:
Understanding the objective and what “good” looks like
Reviewing part prints and models
Defining an initial approach
Developing tooling as needed
Assembling sample parts
Adjusting the process as required
If the initial approach doesn’t meet the requirements, alternate processes or adjustments are explored.
Throughout the process, results are documented, photos and videos are captured, and communication ensures alignment.
The goal isn’t just to assemble parts. It’s to develop a process that meets the defined requirements.
What Gets Evaluated During Process Development
As sample parts are assembled to evaluate the assembly process, multiple parameters are observed and adjusted to understand how the process behaves.
Common evaluation points include:
Forming force
Forming height or displacement
Torque (when applicable)
Cosmetic results
Material deformation or cracking
Process repeatability
These are not evaluated in isolation. The focus is on how they relate to the functional performance of the joint.
How Many Sample Parts Should You Send?
Sample quantity has a direct impact on how effectively the process can be developed.
Typical guidance:
Minimum: 10–15 parts
Used for setup, initial trials, and tooling adjustments
Ideal: 15–20 parts
Allows multiple consistent samples once the process is dialed in
More parts may be needed if:
Multiple materials or rivet designs are being evaluated
You plan to perform your own validation testing
Repeatability needs to be demonstrated
In some cases, components can be reused by removing formed rivets. However, this can damage parts and is not ideal if samples are needed for further evaluation.
In general, more samples allow for better process development and a clearer picture of repeatability.
What You Should Send (and Why It Matters)
One of the biggest factors in successful lab development is the quality of information provided upfront.
To move efficiently, it’s important to include:
The objective: what problem are you trying to solve
Assembly prints showing pre-form geometry and post-form requirements
Component prints and models
Material specifications
Functional requirements (torque, retention, etc.)
A clear definition of what a “good” part looks like
If the process is already being done:
How it is currently performed
What is working and what is not
The most common delay is not understanding what success looks like.
Defining Success: What Are You Trying to Achieve?
Success in lab development depends entirely on the application.
It may mean:
Achieving a specific torque range
Meeting a push-out or pull-out requirement
Holding a form height within tolerance
Producing acceptable cosmetic results
Preventing cracking or deformation
In some cases, success is confirming that the design works.
In others, it’s identifying that a change is needed before committing to equipment.
When functional requirements are clearly defined, process recommendations can be made and validated against those requirements.
What You Receive at the End
At the conclusion of lab development, customers receive a complete summary of the work performed.
This typically includes:
A lab report outlining findings and recommendations
The process used and recommended equipment size
Forming parameters and observed forming force
Tooling recommendations
Photos and videos of the process
If sufficient samples were provided, formed parts are returned for hands-on evaluation.
Common Misconceptions About Lab Development
There are a few common misunderstandings that can slow down the process.
“Can’t we just send one part?”
A single part doesn’t provide meaningful data. Multiple samples are needed to develop tooling and demonstrate repeatability.
“Why do you need to know the material?”
Material directly affects how parts form. Some materials form easily, while others may crack or require special tooling or lubrication.
“Why do you need prints and models?”
Understanding the full assembly and tolerance stack-up is critical to determining whether functional requirements are achievable.
“Why do we need to run samples at all?”
Lab development helps confirm the process, properly size equipment, and ensure tooling geometry meets requirements before production.
What Speeds Up the Process
Lab development moves fastest when expectations and information are clear.
The biggest factors that improve turnaround time are:
A clear definition of what “good” looks like
Complete print and model packages
Defined functional requirements
When these are in place, the focus stays on solving the problem.
The Orbitform Approach
Orbitform’s Solutions Lab is built to reduce risk before equipment is specified.
Multiple assembly processes can be evaluated
Tooling is developed as needed
Sample parts are assembled under conditions that reflect production
Recommendations are based on what works for the part
The focus is on understanding the application and developing a process that aligns with it.
Final Takeaway
Lab development isn’t just about assembling sample parts.
It’s about answering critical questions before moving forward:
Will this design work?
What process is best?
What parameters are required?
What results can be expected?
The clearer those questions are upfront, the more valuable the results will be.
Do you have questions about your current or next assembly design? Contact our team to review how we can help you get answers in our Solutions Lab. Contact Us
Frequently Asked Questions About Lab Testing
What is lab testing in manufacturing assembly?
Lab testing (or lab development) involves assembling sample parts to evaluate processes, tooling, and parameters before committing to production equipment.
How many sample parts should I send for testing?
Most applications require 10–20 parts for initial setup and process development, with more needed for validation or repeatability.
Why is material important in assembly testing?
Material affects how components form, including risk of cracking, required force, and tooling design.
What do I get from a lab testing process?
Typical outputs include a lab report, recommended process, forming parameters, tooling guidance, and sample parts for evaluation.
Can lab testing guarantee production success?
Lab development helps validate feasibility and reduce risk, but final production performance depends on part variation and process control.