Test Engineering deals primarily with the embodiment of systems toward validation and verification activities (V&V) to ensure a test article meets requirements. Implicit in this activity is designing for sufficient Measurement Capability to guarantee the reliability of parametric determinations. The systems that Test Engineers develop range from simple static measurements to sophisticated hardware-in-the-loop (HIL) systems that interact in real time.

Automated Test Systems (ATE) and Special Test Equipment (STE) are traditionally found on manufacturing floors, but have become ubiquitous in commissioning and field applications due to the obfuscation of complexity that facilitates reliable operation by an operator with minimal training. This is especially valuable when systems are commissioned in harsh or remote environments, and is often necessitated by traceability requirements.

Test Engineering demands a high degree of creativity to conceptualize, integrate, and validate systems that are both capable and cost effective. Because single-vendor and commercial off-the shelf (COTS) solutions typically require customizations to achieve this, broad integration experience and established vendor connections are required to develop effective strategies.

TCB Engineers is passionate about Test Engineering and uniquely positioned to solve our customer’s toughest challenges. Leverage our depth of experience and wholistic service offering on your next project.

Core Competencies


  • ATE & STE Systems

    Architecting ATE / STE demands multi-disciplinary depth and breadth of experience to achieve the balance of a cost-effective system that also exhibits sufficient measurement capability. This precipitates the ageless tension of cost vs. performance, which is informed by experience and Engineering principles. Successful Test Engineers possess critical skills across multiple disciplines, including Systems, Electrical, Mechanical, and Software, which allows them to generate outsized value.

    Application Competencies
    Microwave Test & Characterization
    Photonics & Optical Systems
    High Channel Count & Distributed Acquisition Systems
    Anechoic and Open Area Field Test Systems (OATS)
    Signal Processing & Communications Systems
    UL-508 Industrial Control Panels, PLC Integration
    Instrumentation & Control Systems (I&C, SCADA)

    TCB Engineers has designed numerous metrology, controls, and test systems for a diverse client base. We specialize in highly customized Real-Time systems, having deployed them in a variety of scientific, industrial, and MIL-Aero applications. Each system we have produced not only integrates well and looks great, but is designed to be durable, maintainable, and scalable. Leverage our depth of experience to integrate and update cost-effective acquisition, control, and analysis systems.

  • NI Alliance Partner

    TCB Engineers has been a National Instruments Alliance Partner since 2001 and has continuously integrated NI products & services for more than thirty years. This uniquely positions TCB Engineers to provide technical and business expertise that informs decisions and fosters creative solutions. Tempering this enthusiasm is the reality that no single vendor can provide a complete solution for all projects. TCB Engineers strives to find an optimal balance of cost, performance, and ease of maintenance in selecting and integrating National Instruments products.

    NI Competencies
    LabVIEW Real-Time, FPGA, FlexRIO, RF Comms
    Embedded RIO, including custom sbRIO solutions
    TestStand Integration & Deployment
    Motion & Robotic Controls
    IMAQ & Cognex Machine Vision Solutions
    Advanced Communications Protocols
    - Industrial: OPC, CAN, DeviceNet, EtherCAT, and more
    - MIL-Aero: SCRAMNet, ARINC-818, MIL-STD-1553, and more
    - Interconnect: PCIe, DisplayLink, USB, and more

    Leveraging the right combination of NI technologies enables a wide range of application areas and can significantly reduce total implementation cost while providing enhanced capability. TCB Engineers is uniquely positioned to provide complete solutions that leverage NI products to their fullest potential. We are also able to act as a strategic liaison and customer advocate for interactions with NI Sales, Support and Repair.

  • Integration & Fabrication

    Cost-effectively realizing ATE and STE is a timeless challenge due to the number of distinct skillsets required. Good systems architects recognize this and tailor their designs to leverage available resources and capex opportunities. A classic example of this is choice of programming language; Will we conscript our client to outsourcing if we choose one programming language over another? TCB Engineers takes pride in getting to know our client’s capabilities and architecting solutions that allow them to leverage internal resources to maximal effect.

    Integration Capabilities
    RF Systems & Assemblies
    Printed Circuit Board Design & Assembly
    Cable Design & Manufacturing
    Virginia Panel Corporation Interconnect Solutions
    UL-508 Compliant Industrial Machinery & Automation
    Electro-Mechanical Packaging

    TCB Engineers utilizes a team-oriented approach to capitalize upon strategic partnerships with industry suppliers and fabrication partners. Combined with our other service offerings, TCB Engineers has the capability to design and execute cost effective subsystems that seamlessly integrate in the overall systems we produce. In this way, we offer a wholistic solution that meets the most stringent standards for quality.

  • Motion Systems

    Precision Motion Systems continue to play a key role in the advancement of technology, especially in repetitive, hazardous, and non-atmospheric environments. New technologies including piezoelectric motors, protocol support, and controllers whose computational power rivals that of a workstation have brought a variety of applications within practical grasp. However, these advances have also fostered industry verticals, complicating the task of selecting and integrating reliable, cost-effective precision motion systems.

    Past solutions we have designed include sub-micron sample articulation systems for high vacuum applications, microfluidic controllers and stapler testers for medical applications, inkjet platen and 3D printers for industrial applications, fiber alignment systems for telecommunications, and a host of fully integrated articulating industrial tools and testers.

    TCB Engineers has significant experience in the design and integration of precision motion systems and seeks to provide novel solutions that meet or exceed requirements while maintaining appropriate cost-effort-maintainability tradeoffs. Large or small, custom or off-the-shelf, capitalize upon our experience to design your next precision motion system.

  • Gage R&R and SPC

    Is my manufacturing process in control? This seemingly benign question can be quantitatively answered using Gage Repeatability and Reproducibility (GR&R), and Statistical Process Control (SPC) techniques. GR&R is a data-driven approach to quantifying sources of measurement variation, which provides insight to improve measurement quality. SPC is a data-driven approach to controlling, optimizing, and maintaining processes, which provides insight to improve product quality and reduce cost.

    Careful analysis and experience are critical to separating failure mode contributions into those rooted in measurement variation (GR&R) and those related to product quality (SPC). Once in control, a SPC system monitors quality measurements for a statistically significant change and triggers an appropriate corrective action.

    While most Fortune 500 companies embrace some form of DFM-GR&R-SPC process control methodology, many smaller companies struggle to identify a clear value-added proposition and struggle with implementation. Effectively employing them necessitates a challenging combination of interdisciplinary skills to fill, no matter the environment and culture.

    TCB Engineers has extensive manufacturing experience with consumer, medical, and MIL-Aero products. Having successfully transitioned numerous projects to the manufacturing environment, TCB Engineers collaborates intuitively and creativity toward developing novel solutions.

  • Engineers First

    Have a difficult challenge? Experience matters.

    All work at TCB Engineers is performed under a Licensed Professional Engineer and we hold close the principles embodied in the NSPE Engineers' Creed.

    Our Engineers are naturally curious and our ability to solve the tough problems is part of what defines us. With expertise in Signal Processing, Applied Physics & Mathematics, RF & Wireless, and Information Systems, we’re prepared to take on novel challenges and deliver exceptional results.

    See our Systems Engineering service offering

    See our Electrical Engineering service offering

    See our RF Engineering service offering

  • Let's Collaborate

    Contemplating a new development or struggling with an existing one?
    Caught in a cycle of wholesale outsourcing?

    TCB Engineers has extensive experience collaborating with customer teams large & small, which allows organizations to augment skillsets instead of wholesale outsourcing.

    Taking advantage of our Engineering Services can help ensure project success by anticipating risks and forming collaborative strategies that avoid cost and schedule overruns.

    Whether it be invention to entrepreneurship, theory to proof, or ConOps to Phase IV, TCB Engineers is uniquely positioned to be a strategic partner in your next project.

Have a difficult challenge? Contemplating a new development or enhancements to an existing one? While it can be relatively easy to get started with LabVIEW, the complexity of integrating disparate hardware, advanced features, and large applications can become a daunting task.

TCB Engineers has extensive experience in turn-key development, but also working directly with customer teams so they may leverage their strengths through skills augmentation. Taking advantage of our LabVIEW consulting services can help ensure project success by anticipating potential pitfalls and forming collaborative strategies to avoid cost and schedule overruns.

An NI Alliance Partner since 1999, TCB Engineers has developed, modified and improved countless LabVIEW applications for a diverse customer base. We are uniquely positioned to provide Certified LabVIEW Architect (CLA) consulting services and customer advocacy for interactions with various NI groups, including Sales, Support and Repair.

The National Instruments (NI) TestStand Development System is the premier test sequencing host for a wide range of data acquisition and control systems. While it can be relatively easy to get started with TestStand, leveraging advanced features and use models can be a daunting task. TCB Engineers welcomes these challenges and brings to bear more than fifteen years of TestStand experience.

TCB Engineers has extensive experience in turn-key development and architecting solutions for execution by customer teams so they may leverage their strengths through skills augmentation instead of wholesale outsourcing.

Have a difficult challenge? TCB Engineers programmers are degreed Engineers, so our ability to solve the tough problems is what separates us from the competition. Contemplating a new development or enhancements to an existing one? Taking advantage of our consulting services can help ensure project success by anticipating potential pitfalls and forming collaborative strategies to avoid cost and schedule overruns.

Background

Work Product Samples

Most of our work is not in the public domain, but here's a couple examples we can share. 

RF Welder

Balancing size, weight, power, and cost (SWaP-C) isn't easy. See how we helped our customer refresh their product design and maintain their leadership position.
RADAR SAFETY CONTROLLER

We specialize in high reliability designs for harsh environments. See how we engaged in a formal design process to ensure success.
PCBA Test System

Automated test need not be complicated & expensive. See how we helped our customer bootstrap their way into advanced manufacturing.
IoT-Enabled CRDS Sensor for UAV

An academic institution needed a sophisticated UAV payload for research. See how we developed a SWaP-optimized high reliability design with IP-67 rating.