Highly Accelerated Stress Screening (HASS)

Highly Accelerated Stress Screening is a production screening technique that is very useful for identifying manufacturing issues, problems, and process monitoring. The right application of HASS testing can shorten screening times and costs, enhance process management, and boost overall quality.

Talk to an Expert

Highly Accelerated Stress Screening (HASS)

TRUSTED BY

Precision-driven testing for dimensional accuracy and compliance

Overview
Scope, Applications, and Benefits
Test Process
Specifications
Instrumentation
Results and Deliverables

Overview

Highly Accelerated Stress Screening (HASS) is a production-phase reliability method in which units undergo various levels of thermal and vibration stress to induce latent defects, thereby detecting them before they leave the production floor for customers. HASS stress profiles are derived from HALT and operate within defined product limits, ensuring defective units are detected without depleting the life of good units.

HASS is used across various industries, including electronics, aerospace, defense, automotive, and industrial equipment, where reliability is a major concern. HASS is used alongside HALT, where design margin is converted into a repeatable production-quality tool, thereby detecting defects such as solder joint defects, marginal components, and assembly defects that would otherwise pass visual inspection.

Scope, Applications, and Benefits

Scope

HASS covers production-phase stress screening of electronic and electromechanical assemblies using combined thermal and vibration environments derived from HALT qualification data.

Stress profiles defined within operational limits established during HALT
Combined thermal cycling and multi-axis vibration applied simultaneously
Proof of screen (PoS) required to validate profile effectiveness before production use
Applicable to PCBs, electronic assemblies, sensors, power supplies, and electromechanical devices
Covers 100% production screening or statistically defined batch screening
Supports ongoing production quality monitoring and supplier screening programmes

Applications

Electronic assemblies and PCB systems
Automotive components
Aerospace and defense equipment
Consumer electronics
Industrial control systems

Benefits

Removes early-life failures (infant mortality)
Improves product reliability and consistency
Reduces warranty and field failures
Enhances customer satisfaction
Supports continuous manufacturing improvement

Test Process

Pre-Screen Inspection

Products are checked to ensure proper functionality before screening.

Controlled Stress Application

Products are exposed to temperature cycling and vibration within predefined safe limits.

Monitoring and Detection

Units are monitored for failures or defects during stress application.

Screening Outcome

Defective units are removed, and passed units proceed to final delivery.

Technical Specifications

Parameter	Details
Stress Factors	Temperature (high/low), rapid thermal cycling, vibration
Temperature Range	Typically -50°C to +150°C
Vibration Range	Multi-axis random vibration (several Grms)
Test Approach	Controlled stress screening based on HALT limits
Measured Output	Measured Output
Environment condition	Environment

Instrumentation Used for Testing

HASS Chamber
Temperature Control Unit
Multi-Axis Vibration Table
Monitoring Sensors
Data Acquisition System

Results and Deliverables

Identification and removal of defective units
Screening pass/fail results
Reliability improvement data
Process validation insights
Detailed HASS screening report

Why Choose Infinita Lab for Highly Accelerated Stress Screening (HASS)?

Infinita Lab is a leading provider of Highly Accelerated Stress Screening (HASS) and streamlined material testing services, addressing the critical challenges faced by emerging businesses and established enterprises. With access to a vast network of over 2,000+ accredited partner labs across the United States, Infinita Lab ensures rapid, accurate, and cost-effective testing solutions. The company’s unique value proposition includes comprehensive project management, confidentiality assurance, and seamless communication through a Single Point of Contact (SPOC) model. By eliminating inefficiencies in traditional material testing workflows, Infinita Lab accelerates research and development (R&D) processes.

Looking for a trusted partner to achieve your research goals? Schedule a meeting with us, send us a request, or call us at (888) 878-3090 to learn more about our services and how we can support you. Request a Quote

Frequently Asked Questions

HASS is a production screening method that applies controlled environmental stresses to detect and eliminate manufacturing defects, ensuring only reliable products are delivered to customers.

HASS is used in production for defect screening, while HALT is used during development to find design weaknesses and determine stress limits.

The main purpose is to detect early-life failures and manufacturing defects, improving overall product reliability and quality.

Factors include stress levels, duration, product design, and correct setup of screening parameters.

HASS cannot detect design flaws and relies on proper HALT data; incorrect stress levels may reduce effectiveness or risk damaging good products.