Flying Probe Testing
At Active-PCB, we offer advanced flying-probe (fixtureless) testing as a core part of our PCB validation capabilities. This method gives us the flexibility to test prototypes, low- to medium-volume production runs, and boards with tight design constraints, without the need for expensive bed-of-nails fixtures.
Flying Probe Testing at Active-PCB Solutions
Why Should You use Flying Probe Testing for your PCBS?
- No fixtures required: Because flying probes move dynamically, there’s no need to design and build a custom test fixture for each new product.
- Rapid test program development: From CAD files we can generate the test sequences more quickly than would be possible with traditional fixtures.
- High fault coverage: Modern flying probe systems integrate advanced measurement, boundary scan, and functional test capabilities.
- Flexibility for design changes: If your board design changes, we can update the probe paths easily without mechanical rework.
- Ideal for prototypes and lower volumes: While bed-of-nails remains efficient for very high volumes, flying probe excels for smaller runs or varied product mixes.
- Lower cost: Without the need for custom fixtures, the set-up costs are greatly reduced.
Our Flying Probe Capabilities & Equipment
We invest in industry-leading technology to ensure top performance and coverage:
Takaya APT-9411CE Flying-Probe Tester
The APT-9411CE is a modular, high-precision system that in its standard configuration includes 4 flying probes on the top side and 2 fixed probes on the bottom side.
- Board size capability: up to ~21″ × 18″ (≈ 530 × 460 mm)
- Very suitable for mixed-signal, densely populated, multi-layer boards, and offers excellent ease-of-use for rapid program development.
These two testers complement each other to give us broad coverage in terms of board size, complexity, throughput, and feature integration.
What We Can Test and What You Get
When you entrust your board to us for flying probe testing, here’s what we deliver:
- In-circuit and structural tests on component nets
- Short/opens, capacitance, resistance, diode, transistor measurements
- Power-on and functional tests (where needed)
- Full diagnostic data and failure localization
- Support for design-for-testability (DFT) input – we’ll advise on pad placement, trace accessibility, and via strategies to optimise testability
Design Considerations for Better Testability
To achieve optimal test coverage, we recommend:
- Provide test pads or vias on nets that require measurement, ideally two per net when possible.
- Pad sizes of at least 0.25 mm (250 µm) diameter (or 80 µm in special cases) are preferable.
- Uniform distribution of contact points across the board to reduce probe travel distance and test time.
- Accessible layout: avoid blocked areas beneath large components; leave spacing around dense clusters for probe clearance.
- Account for board warpage: stiffeners or support structures can help maintain planarity during probing.
We’d be happy to review preliminary designs and give feedback to ensure your board is as probe-friendly as possible.
Why You Should Choose Active-PCB Solutions for Your Flying Probe Testing
- Dual high-end flying probe platforms to match volume, complexity, and board size
- Integrated test strategies combining flying probe, boundary scan, and bed-of-nails
- Experienced engineers who can optimize both test coverage and runtime
- Rapid test program development, especially for prototypes and NPI
- Full diagnostic reporting and assistance with design-for-test feedback
If you’d like to discuss a particular board or get a quote based on your product’s complexity, feel free to contact us. We look forward to helping you validate and perfect your PCBs.
At Active-PCB Solutions, we’re dedicated to leveraging our many years of expertise and investment in new technology to deliver outstanding results, ensuring that every PCB we produce meets the highest standards of excellence.
Our Flying Probe Testing is just part of our suite of rigorous testing and inspection methods.