At MGA Research Corporation, we regularly support customers developing innovative products that require non-standard structural load testing. For some of these products, their size, weight, application, or specific requirements often demand challenging test approaches for structural proof loads, complex load application geometries, or repetitive cycle procedures.

Over the years, a substantial “toolbox” of structural load testing capabilities has been built that allows our engineering teams to simulate real-world conditions across a wide range of industries. Paired with a highly technical staff, cross-trained in different industries and regulatory requirements, MGA's capabilities to provide simple and elegant solutions to complex problems are increasingly leveraged by our partners in the industries we serve. From electric vehicle platforms and off-road recreational vehicles to heavy trucks and aircraft interiors, MGA works closely with customers to design test setups that accurately replicate the loads their products will experience in service.

The following examples highlight how MGA engineers have addressed unique testing challenges by combining custom fixture design, high-capacity load systems, and creative test methodologies.

Electric Vehicles: Structural Testing and FMVSS Standards

As electric vehicles have become more prevalent, a new structural challenge emerges for vehicle manufacturers. Due to the reliance on large “skateboard”- style battery packs integrated into the vehicle body, significant overall mass has been added.

These design changes affect the regulatory evaluations, such as the application of FMVSS 214 side impact testing and FMVSS 216 roof crush testing. The need for extra structure to protect the battery during collisions has led to increased lateral strength compared to older vehicle designs. As a result, MGA has improved its procedures and equipment to assess these vehicles in accordance with the new requirements.

Our equipment and fabrication team has developed a next-generation FMVSS 214 Side Intrusion and FMVSS 216 Roof Crush test system designed to meet NHTSA and IIHS requirements, capable of applying loads up to 300,000 lbs. The dual-purpose system integrates a high-strength test frame, advanced hydraulic loading equipment, and modern data acquisition with custom software to ensure precise control and accurate results.

This system has also been used in various applications for lateral side loading and other specialized load requirements for larger vehicles, allowing manufacturers to confidently move towards production.

Structural Testing for Off-Road and Recreational Vehicles

As off-road recreational vehicles, especially side-by-side utility vehicles (UTVs), have become more popular, their designs have improved to enhance overall occupant protection in rollover accidents. The roof structures of these vehicles are typically tubular, which presents challenges in assessing their strength. To address this, MGA has developed multiple testing methods: either rotating the frame 90 degrees to load the roof, or modifying MGA’s roof crush system to apply loads vertically.

Because off-road vehicles often feature highly stylized body designs, each test requires careful planning and fixture design to ensure the loads are applied accurately while maintaining realistic boundary conditions. By combining creative engineering approaches with flexible load systems, MGA helps manufacturers ensure the strength and safety of rollover protection structures.

The Challenge for Large Trucks

In recent years, large trucks have evolved due to significant increases in package delivery volume, electrification, and enhanced aerodynamic features. These and other modifications have driven the need for creative load and cycle testing applications in truck development. Examples have included high-load testing in accordance with FMVSS 223 requirements for underride protection systems.

In several programs, MGA engineers configured test setups that allowed entire cab and trailer assemblies to be positioned within the laboratory, enabling load equipment to apply forces directly to the rear structure of the trailer. This approach allowed manufacturers to evaluate the system in a configuration that closely represents real-world conditions.

Other applications for heavy trucks involve durability fatigue testing on component sub-systems. In these cases, custom fixtures are designed to handle high loads, sometimes up to 50,000 lbs. The main purpose of the fixture design is to secure the assembly in an “in-use” orientation. Multiple dynamic-rated load cylinders are then used to apply load to the assembly through a simulated lifetime of use. These evaluations are conducted over several weeks with daily inspections for wear, cracks, and other issues.

One of the most dangerous situations a large or commercial vehicle can experience is a rollover event. These scenarios pose large risks to occupant safety, particularly due to deformation of the vehicle into the occupant compartment, also known as the “survival space”. As a result, MGA has developed a multi-purpose test system specifically designed to replicate a real-world crash. The system can be configured to feature a large platen which is hydraulically controlled to simulate the forces a vehicle will experience during a rollover. Various standards, such as ECE R29 and SAE J2422, are used to assess the integrity of the survival space following the test. MGA’s test system has been designed with these regulations in mind, but can also be adjusted to accommodate a wide range of test parameters so that any rollover scenario in which the roof of a vehicle is damaged can be recreated.

Aerospace Structural Testing for Aircraft Interior Systems

Certain segments of the aircraft industry have undergone significant advancement over the past few years. These areas include first/business class accommodation and luxury private jets. The goal of this advancement has been to provide an enhanced travel experience for the customer.

Airworthiness standards require these designs to be able to withstand numerous high load conditions. These requirements result in test protocols that have a very high degree of cylinder placement variability.

MGA has developed a system that provides easy cylinder adjustments for multiple complex load conditions. This facility is supported by a ground level reaction mass to support high loading. Various commercial and private jet applications, such as bulkheads, suites, and cabinet designs, have been evaluated with this capability.

Other applications for the aircraft industry include static rapid decompressions testing using the facility shown below. With an ability to apply upwards of 40 metric tons of load in the normal direction of each panel, totaling over 100 different loading points while controlling the load at each location. The main purpose of this test is to ensure a rapid cabin decompression, often caused by puncture of the fuselage, could be contained within the panels of the furniture installed and protect occupants while landing safely.

Partner With MGA for Complex Structural Testing

MGA combines high-capacity load systems, custom fixture design, and experienced test engineers to support challenging structural evaluations across automotive, commercial vehicle, off-road, and aerospace industries.

Whether your program requires testing to meet FMVSS standards, durability fatigue evaluation, or a completely custom structural load application, our team works collaboratively with customers to develop test setups that deliver accurate, repeatable results.

For more information on our unique capabilities related to structural load evaluations, or to schedule a meeting, please contact us. We look forward to collaborating with you to help you reach your goals and drive innovation.

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