12 reviews

Aircraft Structural TestingAerospace Structural Durability and Fatigue Testing

Structural durability and fatigue testing are essential for ensuring the safety, performance, and certification of aircraft structures. Dewesoft provides a flexible DAQ platform designed for high-channel-count, high-dynamic-range measurements in both static and dynamic conditions. From material strength and static load to lifetime fatigue, our scalable systems adapt to demanding test setups where failure is not an option.

Our solution supports everything from full-scale airframe tests to component-level material evaluations, capturing high-fidelity data across thousands of channels with synchronized inputs from strain gauges, force sensors, displacement, temperature, vibration, and more.

Stress and Strain analysis

Full Bridge

Quarter Bridge

Half Bridge

Force

Displacement

Vibrations

Acceleration

Temperature

RTD

Thermocouple

Thermal video

Voltage

Current

Digital IO

Analog out

Video

High-speed video

TEDS compatible

Sequencer

FFT analyser

Order tracking

Ethernet

EtherCAT

PTP synchronization

openDAQ compliant

ARINC 492

MIL-STD-1553

iNET

IRIG Chapter 7

IRIG Chapter 10

Aircraft Structural Testing highlights

Precision measurement & analysis

Capture synchronized strain, displacement, force, and temperature data. Analyze stresses, crack propagation, and fatigue life from multiple angles.

Scale and grow

Acquire 10,000 channels measuring strain and many other sensing or signal types in a centralized or distributed way, with a software that adapts to your needs without losing overview.

Long term reliable measurement results

The DAQ system is optimized towards minimizing long term drift, suppressing electromagnetic noise and cable length. Our calibration units offer you the flexibility of "traceability on the fly”.

Static to highly dynamic sampling rates

Analog amplifiers that are easily able to go from static and fatigue testing in durability, to high-speed structural dynamics to transient recording in impact testing (wing break test, bird / drone strike, drop test, or crash) - all with one single software, easy to learn.

Software included

Every Dewesoft system is bundled with our award-winning DewesoftX data acquisition software. The software is easy to use but very rich and deep in functionality: live analysing stress, fatigue and life-time and powerful multi panel data visualization. All software updates are free with no hidden licensing or yearly maintenance fees.

Multi-user software operation

Our software that scales from single to multi user setups. DewesoftX NET lets teams - local or remote - analyze the same data simultaneously, accelerating collaboration without compromise - anywhere, anytime. No additional seat licenses are required for viewing and analyzing the data.

Synchronized acquisition of multiple sources

All channels are time synchronized in the sub microsends, based on Ethernet PTPv2 and can be combined with other systems in place. Seamlessly integrate load control signals, digital image correlation (DIC), standard / high-speed or thermal IR cameras, thermal image correlation (TIC), pressure scanners, or digital avionics networks in copper bird, iron bird or flight test instrumentation (FTI).

Seamless test bench integration

Integrate in real time via EtherCAT (ESI/ENI) with control systems, and simultaneously via Ethernet with PTPv2 sync to your openDAQ ecosystem. Use MQTT or OPC UA for remote access and cloud/on-premise connectivity. Stream data for analytics, correlate with FE simulations, or feed digital twin models in Python (ML/AI).

Avionics data busses support

Direct support for acquisition of digital data from standard Avionics data busses and telemetry standards such Ethernet, ARINC-429, MIL-STD-1553, CAN, iNET, CHAPTER 10, CHAPTER 7.

Open-loop MIMO modal testing

Dewesoft systems are used in such ground-based structural tests to identify modal parameters, validate structural integrity, and support FEM correlation. This approach is particularly useful in programs where GVT is not required or already completed, and where confirming the absence of structural changes is the main goal.

SISO, SIMO, MISO, MIMO modal testing methods

Dewesoft supports a wide range of modal testing methods, including single-reference shaker tests, as well as single-reference roving hammer or roving accelerometer setups. Multi-reference shaker and roving hammer tests are also fully supported, offering flexibility for both simple and advanced structural testing scenarios.

Unified Platform

Combine multiple structure test applications with a scalable eco system - static load, maximum load, fatigue, structural dynamics, transient testing (bird / drone strike), but with the same single easy to use and modern software DewesoftX, limiting training effort and maintenance, keeping efficiency at the highest level.

Lab and in-flight usage

With the support of typical aircraft data busses (ARINC-429, MIL-STD-1558) and data telemetry (iNET, IRIG-106 Chapter 10 and Chapter 7) our system easily allow you to also take your equipment into the air.

Dewesoft quality and 7-year warranty

Enjoy our industry-leading 7-year warranty. Our data acquisition systems are made in Europe, utilizing only the highest build quality standards. We offer free and customer-focused technical support. Your investment into the Dewesoft solutions is protected for years ahead.

Your partner beyond product

Two decades of experience with NASA, Airbus, Boeing, and others in commercial and defense projects. From landing gear, wing and fuselage fatigue, to full-scale structural durability and fatigue testing. We deliver turnkey solutions - from FAT/SAT to on-site training & support. We cover the full structural engineering and validation workflow from CAE to applying strain gauges and stress correlation.

Introduction – Aerospace Industry & Structural Testing

Aerospace equipment and structures must withstand extreme environments and mechanical stresses, where failure can have mission-critical consequences. To ensure safety and reliability, real-world physical testing focused on structural durability, material strength, static and maximum load, as well as lifetime fatigue, plays a vital role—especially in meeting the strict requirements for aircraft type certification.

Structural durability is closely tied to operational safety and long-term reliability. It often overlaps with structural dynamics, including vibration and harmonic analysis. In emerging electric aircraft programs (AAM/eVTOL), structural dynamics tests are sometimes performed before durability testing—often with the same DAQ equipment but at lower channel counts.

Global leaders trust Dewesoft for precise structural data in long-term validation projects. Our solutions are used to test full-scale structures, airframe components, rotorcraft parts, and sub-systems. These tests ensure structural resilience under static loads, compliance with lifetime fatigue requirements, and overall safety and performance—critical for successful type certification.

Structural Durability and Fatigue Testing Overview

Prior to its maiden flight, aircrafts undergo rigorous full-scale testing on specialized test stands to simulate anticipated operational, maximum and ultimate loads. These comprehensive tests precisely evaluate structural behavior under diverse conditions, ensuring early detection of potential design flaws and guaranteeing the highest levels of safety and reliability in service.

Full-scale structural durability and fatigue testing typically last a few years simulating several times the lifetime of the aircraft ensuring designed structural integrity and remains essential in aircraft testing because of the following critical reasons:

Safety: Ensures that the overall structure and all elements support their intended loads without collapsing, protecting occupants and users from harm,
Life-time Durability: Helps structures withstand environmental factors like weathering, seismic activity, and aging, extending their lifespan,
Real-World Complexity: Simulates combined stresses (vibration, gusts, pressurization cycles), reveals how joints, welds, and assemblies behave under long-term cyclic loads, that component-level tests can’t replicate,
Cost-effectiveness: Prevents costly recalls, repairs and maintenance by identifying and addressing potential issues early,
Failure Mode Discovery: Uncovers unexpected cracks or fatigue paths in full-system geometry (e.g., wing-fuselage interfaces),
Performance: Ensures that structures perform their designed functions reliably throughout their intended lifespan,
Validation of Simulation Models: Benchmarks and refines digital twin/FEA predictions with empirical data,
Regulatory Compliance: Mandated by FAA/EASA to certify airworthiness and safe operational life, maximum and ultimate load cases.

Bottom Line: While structural fatigue simulations of components based on Finite Element Methods (FEM) as part of Computer Aided Engineering (CAE), and structural testing of components reduce time to market and risk, full-scale structural and fatigue testing is the gold standard to ensure that the aircraft survives decades of real-world operation.

Example: Airbus A350’s full-scale test subjected the airframe to 165,000 simulated flights (2.5x design life) to validate safety margins

Dewesoft DAQ Solutions for Aircraft Structural Testing

Dewesoft provides high-performance, openDAQ™-compliant data acquisition systems for a wide range of aircraft structural tests. Our flexible, scalable hardware and software are ideal for collectina and analyzing data for certification, development, and experimental testing—from individual components to full-scale airframes.

✅ Qualification & Certification Testing

FAA conformity testing
Qualification and acceptance testing
Defense and space agency programs (e.g., DoD, NASA)

✅ Component & Sub-Element Testing

Static and fatigue testing up to 3.5 million pounds
3.500-kip universal test machines
Non-ambient temperature testing
Modal tests

✅ Full-Scale Development Testing

Static and fatigue tests on large structures
Combined environment testing (e.g., load + temperature)
Air loads and calibration
Control system verification
Modal tests

✅ Small & Medium-Scale Development Testing

Static, fatigue, and mechanism testing
Pressure and high-velocity impact testing
Extreme environment simulation
Powertrain and transmission testing

✅ Materials & Environmental Testing

Composite and metals testing (static and fatigue)
Standard and custom test protocols
Environmental cycling: Temperature, Humidity, Combined conditioning

✅ Experimental Mechanics

Full-field displacement and strain measurements

Data Acquisition Software for Structural Durability Testing

Dewesoft offers measurement and data acquisition solutions for structural durability and fatigue testing, giving manufacturers a cockpit validating stress and fatigue, improving durability, reliability and safety of structural designs. Software is the key in getting insights you can trust.

Award winning DewesoftX software with on the fly data analysis

Handles thousands of channels with low-latency processing.
Online and post process data analysis in one software.
Cluster your signals without losing overview (wing left, wing right, fuselage, etc.).
NET technology acquires data from multiple clients serving multiple users at the same time.
Check your channel health with a mouse click before start.
Set up sophisticated notifications and alarms, for also safety interlocks.
Record long-term sensor and signal data - uninterrupted, multiple files.
On-the-fly calculations with strain gage rosettes, math channels, statistics, filtering, integrals, derivatives, strain-life (ε-N), damage calculation (S-N, material database), class counting, cycle counter, crack growth models, add your own.
Powerful real-time data visualization and analysis: 2D (y-t + prediction lines, y-x, polar diagram), 3D animated finite element (FE) also ready for modal analysis.
Use multiple visualization panels (tabs) on multiple screens.
Remote control and visualization.
Automate your large data sets flow with the sequencer and modern scripting.
Acquisition of digital data from standard Avionics busses (ARINC-429, MIL-STD-1553, CAN and many more).
Calibrate all channels with the same software.
… and more to come on your demand.

After 25 years of DewesoftX software development and many hours of improvements, you can make the award-winning and future proof data acquisition software your next generation cockpit. We have earned the trust of thousands of test engineers around the world, simplifying all relevant steps from setup to advanced data analysis of complex datasets.

Data Acquisition Hardware for Structural Durability Testing

Dewesoft offers open measurement and data acquisition systems for structural durability and fatigue testing, giving manufacturers precise insights you can trust, validating and improving the durability, reliability and safety of structural designs.

Scalable hardware setups

Highly accurate strain gage bridge inputs in ¼, ½ and full bridge configuration.
DC or Carrier Frequency (CF) bridge excitation suppressing noise.
Strain gauge ¼ bridge in 3- or 4-wire configuration compensating cable length resistances.
Flexible and quickly adaptable frontend (push-in terminals, RJ14/RJ45, DB9, LEMO, etc.).
Industry-leading accuracy detecting microstrains in critical components.
Universal inputs for maximum flexibility.
TEDS support for sensor recognition and automated channel setup.
Centralized or distributed data acquisition systems scaling to thousands of measurement channels.
Ethernet and openDAQ ready allowing multiple data streams.
Time synchronous multi-channel data acquisition supporting PTPv2, IRIG-B, GPS.
Redundant parallel data streams and recording, maximizing reliability.
Integrate 3rd party hardware in a time sync’d way like Digital Image Correlation (DIC).
Bi-directional real-time connection to test control (EtherCAT integration).
All channels software-configurable.
Calibration hardware as a product working with DewesoftX.
External calibration reference support.

Testbed Control Integration

State-of-the-art structural durability and fatigue testing programs rely on test controllers applying customizable loading profiles around the complete airframe structure.

Automated test sequences allow a stepped loading and drive highly synchronized multi-axis actuators (servo-hydraulics, electric). This can be extended by environmental simulation (thermal, altitude, combined loads).

The applied load profile is visualized. Safety interlocks & limit checks prevent overloads. Alarms allow an automatic shutdown for critical conditions.

Dewesoft’s data acquisition solutions offer several ways for bi-directional integration with test control systems such as MTS, Moog, etc.:

EtherCAT
Ethernet (openDAQ, MODBUS, OPC/UA and MQTT)
CAN bus
analog/digital I/O

A bi-directional integrated approach of your measurement equipment with load control streamlines your test setup and calibration, and simplifies the acquisition of high-quality data, accelerating your next test program from small to high-channel setups, from lab to in-flight.

Open by Default – Fully openDAQ™ Compliant

Dewesoft DAQ systems are built on the openDAQ™ framework—an open, modular ecosystem for measurement, data acquisition, and testing. Designed with flexibility in mind, openDAQ™ simplifies everything from device discovery and configuration to high-speed data streaming and diagnostics.

All new Dewesoft hardware is fully openDAQ-compliant and open by default. This ensures seamless integration into your workflows while supporting a wide range of industry standards.

To help you get started quickly, openDAQ offers ready-to-use examples and AI-powered tools for effortless integration and fast data access—so you can focus on insights, not setup.

Vibration Shaker Testing: Sine Processing for Structural Validation

During aircraft structural tests, certain resonant frequencies can dominate and overstress components—potentially leading to test failures or inaccurate results. Dewesoft’s sine reduction solution intelligently identifies and removes dominant sine tones in real-time, reducing risk to the test object while maintaining data integrity.

Our system performs real-time data acquisition and FFT analysis of acceleration signals, identifying dominant sine tones in the vibration spectrum. These tones are extracted and fed back into the vibration controller for test profile optimization.

By applying real-time spectral analysis and feedback control, the system helps avoid over-testing, shortens test durations, and ensures compliance with safety and certification requirements. It’s a powerful enhancement for structural durability and fatigue tests, especially when working with large or sensitive airframe structures.

Learn more:

Solution page: Dewesoft’s Sine Reduction Test Solution
Real-world case study: Structural Testing of Rocket Nose Cone Using Sine Processing

Sine processing vibration shaker DAQ system

Turnkey Solutions Beyond Product

Dewesoft gives you extra value.

Privately owned European company with an agile mindset.
Produced in EU with highest quality standards.
Industry-leading 7-year warranty.
Your investment is protected for years ahead.
Two decades of experience with NASA, Airbus, Boeing, in structural projects.
One-stop shop for many testing solutions with one software eases your training effort.
Highly skilled project management team and support (remote and local).
Turnkey systems project management team with FAT/SAT to on-site training & support.
Seamless integration support of our own or 3rd party devices.
Free and customer-focused technical support - talk to real engineers.

We cover the full structural engineering and validation workflow from Computer-aided engineering and mechanical analysis around structural durability and fatigue (FEA), strength, structural dynamics, stability, thermal and fluid mechanics (CFD), to physical testing in applying strain gauges, setting up DAQ and software to data correlating afterwards - get inspired by Dewesoft INSPIRETECH.