What is a Drop Test? Parameters, Standards, & Benefits

In the current competitive business environment, product reliability and safety are driving factors for building customer trust and brand image. Products, particularly packaged products, electronic devices, automotive parts, and consumer durables, are first subjected to comprehensive quality inspections before being delivered to end users. Among the most prevalent and effective ways to test the durability of a product is a drop test. 

A product that fails a drop test not only risks customer dissatisfaction but can also lead to financial losses due to returns and repairs. As a result, businesses are increasingly investing in advanced testing technologies and methodologies to evaluate product durability effectively. By prioritizing reliability and safety through robust testing protocols, businesses can enhance their reputation, reduce return rates, and cultivate long-lasting relationships with their customers.

What is a Drop Test? 

A drop test is a quality control technique applied to assess how a product or package performs upon impact when falling. It mimics random drops while handling, shipping, or storing to detect vulnerabilities and ensure structure. By performing controlled drop tests, manufacturers are able to ascertain if a product will withstand anticipated stresses, minimise transit damage risk, and meet global safety regulations. 

Key Parameters of Drop Testing

Drop testing is an essential technique for testing the ability of products and packaging to withstand impacts and protect contents. Through physical testing or simulation, the following major parameters have a significant effect on the results and information obtained from a drop test: 

1. Drop Height: The drop height of a product or package dictates the impact velocity and, therefore, the amount of energy absorbed by the object. This energy can lead to damage or failure of sensitive products. In the electronics sector, devices like smartphones and tablets are often subjected to drop tests from various heights to simulate real-world scenarios and ensure that they can withstand accidental falls.
2. Product orientation: The way a product is oriented during a drop can significantly affect the impact severity and stress distribution across the item. For instance, in the food industry, glass jars that fall upright tend to have a different impact response compared to those that fall sideways.
3. Drops Quantity: The cumulative effect of multiple drops can provide insight into long-term durability and performance characteristics. In consumer electronics, products like laptops or handheld devices must undergo extensive drop testing—often multiple drops are simulated from different heights—to evaluate how repeated impacts affect their structural integrity over time.
4. Material of Impact surface: The surface material onto which a product is dropped plays a critical role in the amount of energy absorbed during an impact. Industries relying on fragile materials, such as glass and ceramics, must prioritize testing on various surface materials to ensure products are designed to withstand specific environments.
5. Temperature and Humidity: Particularly relevant for packaging from cardboard, temperature and humidity may influence material properties of the product, packaging, and surface of the drop.
6. Data collection and Analysis: Engineers record data on impact magnitude, functionality, and cosmetic damage during and after the test. 

Steps to Conduct a Drop Test

A drop test consists of several steps, such as defining the objective, selecting the test sample, setting the drop parameters, preparing the test setup, conducting the drop, recording the results, analysing performance, and reporting and making recommendations.

Step 1: Define the Objective

The initial step is to identify the purpose of the test— whether it is to assess the product’s durability, the packaging’s performance, or adherence to certain industry standards. An objective ensures that the test environment replicates the real-life risks the product can encounter. 

Step 2: Select the Test Sample

A representative sample of the package or product is selected for testing. The sample should be representative of the actual production quality, such as materials, dimensions, and weight, to supply accurate and reliable results. 

Step 3: Set the Drop Parameters

Key parameters, including drop height, orientation (face, edge, or corner), number of drops, and surface type, are established according to standards (e.g., ASTM, ISTA, or ISO) or corporate requirements. These parameters mimic real-world handling and transit conditions.

Step 4: Prepare the Test Setup 

The drop test apparatus or drop tester is set to provide precise and consistent results. The area where testing is done must contain a flat, rigid impact surface. The sample is subsequently set in place according to the selected orientation prior to release.

Step 5: Perform the Drop 

The product is dropped from the established height in free-fall conditions without the use of any externally applied force. Every orientation is individually tested (edge, corner, and flat side) in order to record all the possible impacts of actual handling.

Step 6: Note and Record the Results 

After every drop, the sample is examined for visible damage like cracks, deformation, or functional failure. Accurate measurements, photographs, and test notes are taken for assessment. Internal performance tests, if applicable, are performed as well.

Step 7: Analyze Performance 

The data gathered is compared to predetermined acceptance criteria or standards. Through this analysis, it is determined if the product passes safety and durability requirements or if design/packaging enhancements are required.

Step 8: Report and Recommendations  

A comprehensive test report is made up of test conditions, the number of drops, observation of damage, and compliance status. The manufacturers can make design modifications, enhance packaging materials, or reinforce weak points based on the test results. 

Common Standards of Drop Test 

For consistency and worldwide acceptability, drop Testing are conducted according to known international standards. These standards specify test procedures, parameters, and acceptance criteria enabling manufacturers to compare product durability and packaging reliability.

1. ASTM D5276 (American Society for Testing and Materials)

This standard outlines the protocols for free-fall drop testing of loaded containers. This standard emphasizes the importance of evaluating package durability by dropping them in various orientations, including corners, edges, and faces, which helps in validating packaging effectiveness, particularly in the context of shipping and logistics.

1. ISTA (International Safe Transit Association) Standards

ISTA standards consist of multiple series, such as ISTA 1, 2, and 3, each tailored to address different shipping and transit conditions. For example, ISTA 1A focuses on straightforward drop testing for unit-packaged products, assessing their robustness during handling. In contrast, ISTA 3A simulates more complex distribution environments, incorporating factors like drops, vibrations, and compression to evaluate packaging resilience under realistic shipping scenarios.

1. ISO 2248 (International Organization for Standardization)

The ISO ISO 2248 standard outlines procedures for vertical impact testing, often referred to as free-fall testing, for fully loaded transport packages. By establishing a consistent framework for assessing packaging performance, this standard ensures that products can withstand the rigors of global market distribution, leading to improved reliability and safety in packaging practices.

1. MIL-STD-810 (Military Standard, U.S. Department of Defense)

MIL-STD-810 is a military standard developed by the U.S. Department of Defense, specifically designed for defense and aerospace equipment. This standard includes comprehensive drop test procedures that simulate extreme handling, shipping, and usage environments, making it significantly more rigorous than typical commercial packaging requirements. Its emphasis on durability ensures that military equipment can withstand challenging conditions.

1. IEC 60068-2-31 (International Electrotechnical Commission)

IEC 60068-2-31 is a standard established by the International Electrotechnical Commission that pertains to electronic and electromechanical products. It outlines drop and topple tests that are essential for determining whether consumer electronics can endure the stresses associated with handling. The rigorous testing within this standard helps to ensure that everyday electronic devices remain functional and reliable after potentially damaging impacts.

Benefits of Conducting Drop Testing

Drop testing, a very important quality control process, has numerous advantages such as increased product reliability, minimized damage costs, better customer satisfaction, and confirmed conformity to industry standards.

Better Product Durability

Drop testing enables manufacturers to identify potential weaknesses in product design, enabling them to address the required changes to ensure the product can handle actual use and unintentional drops.

Minimized Damage Costs

Conducting drop tests lessens the likelihood of damage during shipping and handling by pinpointing vulnerabilities and enhancing packaging, which leads to a decrease in returns, replacements, and overall costs.

Compliance with Industry Standards Guaranteed

Most industries have standards for drop testing of packages to prove product safety and reliability. Drop testing assists manufacturers in complying with these standards, reflecting a dedication to quality.

Optimized Packaging Design

Drop testing gives important information on the performance of various packaging materials and designs. This enables optimization, utilizing the appropriate materials and design to save the product at the lowest cost.

Reduced Returns and Replacements

By detecting potential problems prior to products reaching customers, drop testing reduces the risk of damage and thus decreases returns and replacements, saving time and money for both the manufacturer and the customer.

Presto Instrument Drop Testing Machine

To achieve precise and reliable drop test results, selecting the right testing machine is essential. The Presto Instrument Drop Testing Machine allows for accurate modeling of free-fall conditions. It is designed for testing corrugated boxes, containers, and various packaging materials under controlled parameters.

With adjustable drop heights and a robust construction that adheres to international standards, this machine helps manufacturers effectively evaluate both the strength of their products and the integrity of their packaging. Presto's drop testing machines are highly regarded across all industries for their reliability, consistency, and ease of operation, making them the preferred choice for quality control and R&D centers.