Design, Simulation & Testing Capabilities

Design, Simulation & Testing Capabilities

Senior Flexonics is committed to using the latest technologies and tools in the development of its products.  World class modeling and analysis are crucial in today’s fast paced environment, and are a cornerstone of the development process at Senior.

Senior Flexonics’ Engineering staff rigorously adhere to a virtual validation methodology, which arms all levels of the engineering staff with CFD and FEA programs to both iterate and validate their products.  This commitment allows both for significant risk reduction as well as faster product cycles.

Virtual Modeling

3-D Solid Modeling

  • C3P
  • UG
  • Solid Works
  • Pro-E
  • Auto CAD

3-D Rapid Prototyping


Analysis Lead Design

  • Stress Analysis
  • Modal Analysis
  • Fluid Dynamics (CFD)
  • Data Processing
  • Fatigue Life


Product Instrumentation

  • Strain
  • Acceleration
  • Velocity
  • Temperature
  • Pressure
  • Flow

Data can be collected either in a laboratory or vehicle setting. Data can be used to develop validation tests as well as for solving problems.


Laboratory Testing


Vehicle Testing

Prototype Laboratory

  • Located in Bartlett, IL
  • 24,000 Square Feet
  • Experienced Staff
  • Open 120 hours/week
  • Assembly, Machining, Testing


Testing Capabilities

The data collection, analysis and destructive testing facilities at Senior Flexonics include an array of different tests to ensure quality and durability.

Available Tests

  • Static Spring Rates
  • Dynamic Spring Rates
  • Squirm Testing
  • Full system testing
  • 1, 2, 3, 6 DOF MTS Testing
  • Temperature up to 870°C
  • Burst Pressure
  • Vibration Analysis/Durability
  • Temperature up to 870°C
  • Salt Spray Test
  • Custom Test Development

A small example of the tests Senior Flexonics performs at our Bartlett Laboratory Facilities.


Squirm Testing Bench


High Temperature Testing


Torque Testing


Vibration Endurance Testing

Non Destructive Testing Services

  • Positive Material Identification (PMI)
  • SEM
  • Fluorescent Penetrant Inspection
  • X-ray Imaging
  • CT Imaging

A small example of our non destructive testing.


Fluorescent Penetrant Inspection


CT Imaging


X-ray Imaging