- Do screws back out?
- If special tools are needed, do we have enough of them? Torx, Allen, etc?
- During assembly
- Does it feel solid?
- If there are points of weakness, where are they?
- Anything obviously wrong should be noted
- Do the buttons actuate? Anything interfering with them?
- Static Electricity testing
- Electrical shorts through housing?
- Do cables fit securely?
- Do they break contact?
- Does the housing interfere with cable connections?
- Squeeze the device and look for any changes in behavior or fit/finish
- Shake the device, listen for loose PCB or other parts
- If the device has mounting affordances, mount it
- How much force is required to remove it?
- How much force is needed to mount it?
- Can it be twisted off of the mounting surface/area?
- How do finishes hold up with abrasion?
- Is the device easily cleanable?
- Do housing components assemble/align well?
- Has intended design symmetry been preserved?
- Are corners broken? Any obvious burrs?
- Are fillets present?
- Holes in housing for connectors
- What is the appropriate torque application for screws? Are electric screwdrivers not advised?
CAD Sanity Check¶
- Have we made sure that all parts are final production units and not holdovers from prototyping?
Tolerances and Standards¶
Measure Against Drawings, check against Codeshelf standard tolerances (on drawings)
- Any surface finish callouts on drawings should be checked against finished parts
- Note any obvious mechanical flaws on mating surfaces
- Note cracks, flaws or imperfections
- Corners rounded/broken? Check for sharp edges
- Look for mars, scratches
Mechanical Fit and Alignment
- Test-fit mating parts and examine for alignment issues
- Assembly Tests
- Assemble fully
- Tighten screws
- Check for gaps in mating parts
- Housing ports/holes for connectors
- How close is the fit around the cable?
- Does the cable break contact?
- Functional Tests
- Do buttons function as intended, mechanically?
- Are they aligned in their openings?
- Is the screen aligned with the edges of the housing?
- Are all pixels visible?
- Do screws back out?
- What happens when you overtighten them?
- Endurance Tests
- Drop Test
- Drop device from the height it is normally used from/mounted at
- Shake Test
- Vigorously shake the device and listen for rattles and other sounds, note them
- Cable pull/Twist
- Insert cables and pull them out.
- Note how much force is needed
- Note any breakage or loose parts
- Squeeze Test
- Squeeze the assembled device with your hands and look for gaps in the housing, note any sounds or breakage