testXpo highlights 2019

zwickiLine Z2.5 TN+ for spring simulation

With zwickiLine Z2.5 TN+ and testXpert III, ZwickRoell offers the ideal solution for the simulation of spring forces of autoinjectors. Use of this testing system significantly reduces development efforts and costs, since the use of real springs is eliminated. High product safety is ensured through the load capacity of the springs, even with changes in viscosity, and possible recalls due to incomplete injections is avoided. The high resolution of the crosshead movement and superb speed accuracy, even at very slow test speeds and short test travel, deliver reliable test results.

Testing system:

  • A powerful wear-free AC motor enables a high crosshead speed of 3000mm/min over the entire force range up to 2.5kN.
  • The high resolution of the crosshead movement of 0.95 nm and superb speed accuracy with 18µm/min, deliver reliable test results even at very slow test speeds and short test travel distances in the µm range.

Advantages and benefits:

  • With the simulation of spring forces, the costly use of real springs during development of autoinjectors can be eliminated, and development efforts can be reduced.
  • The functioning of spring loaded devices, even with changes in viscosity during storage, can already be tested in the development phase. This ensures product safety and helps avoid possible recalls due to incomplete injections.
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Automated testing of auto-injectors

With help from autoinjectors, liquid medications can be administered directly and easily in a single dose, making them subject to stringent quality control. With ZwickRoell’s multifunctional testing machine, all component tests that are part of an autoinjector or pen are tested. Through daily checks all relevant testing parameters are reviewed, significantly elevating safety and test results. In combination with the automation solution roboTest, operator influences are eliminated and high reproducibility of test results is achieved.
Testing system advantages and benefits:

  • All components tests on the autoinjector are performed in one cycle. A results file for all components tests is generated and guarantees high reproducibility. With a reduced number of samples, costs are lowered and human error due to sequential process and one specimen is avoided.
  • Faster cycle times (< 3min with all currently available options) and comfortable expansion options for fully automated feeding of specimens using robotic systems.
  • Reliable test results are guaranteed through daily checks of force, weight, needle length, liquid flow, injector color, and acoustics.
  • The separate electrical cabinet fulfills basic requirements for hygienic design (GMP)
  • Mistake-proofing through design (combination Poka Yoke with scanner) to prevent incorrect insertion of specimens. This leads to reliable test results and reduces costs.
  • Universal cap remover (gripper) enables design independence of injector caps.

roboTest advantages and benefits:

  • Operator influences are eliminated with the use of roboTest. This results in high reproducibility of the test results.
  • Easy insertion of the roboTest specimens helps avoid user errors and therefore guarantees reliable test results.
  • Through roboTest, qualified personnel are relieved of routine tasks, making them available for more complex responsibilities.
  • High reproducibility of test results is achieved with the standardized specimen magazines.
  • With use of the automation system, a reduction in cost per specimen is achieved. Rapid amortization of the system is an additional benefit.

AllroundLine Z005 for catheter testing

In medical technology catheters fall under the highest risk classification and strict quality requirements. With the AllroundLine Z005 for catheter testing ZwickRoell provides the perfect testing system. Realistic and body-like conditions allow all tests to be as authentic as possible. Automated processes and the variety of submersible specimen grips and fixtures, allow ZwickRoell to provide reliable test results, and ultimately product safety for doctors and patients.

Advantages and benefits

  • The large test area facilitates the installation of several catheters to be tested at the same time
  • The test area is adapted to market standard catheter lengths and allows for processing of realistic tests.
  • Tests under body-similar conditions (temperature, pH value) are easily performed
  • Minimization of operator influences through automated processes
  • Flexible application possibilities for research and development, and production
  • Flexible and exact fastening options for different types of vessels, for accurate simulation of the test environment
  • Reliable test results with submersible specimen grips and fixtures through accurate, reproducible processes



  • Quality testing on rubber specimens for batch release during production

Key features

  • Oil-free and low-maintenance drive technology with low operating and maintenance costs.
  • Displacement measuring system coaxial to the test axis and positioned close to the specimen.
  • Precise control via 10kHz frequency, enabling rapid reaction to spontaneous events
  • High-precision, fatigue-resistant 2-column test frame with integrated
  • T-slotted platform and collection trough.
  • Demand-based and steplessly controlled air cooling for low-noise operation.
  • Can be used with temperature chambers

Advantages and benefits

  • Ideal for quasi-static and dynamic applications with the benefit of being able to use the complete static and dynamic ZwickRoell product portfolio.
  • Low operating and maintenance costs with oil-free drive technology without additional supply feeds.Motor-driven crosshead adjustment for convenient operation.
  • Intelligent testing software featuring intuitive operation - testXpert R for dynamic tests and testXpert III for static tests.
  • The patented electromagnetic drive was designed specifically for the speed range relevant to testing technology and features exceptionally quiet operation, optimum control quality, and extremely high positioning accuracy.
  • The travel measuring system is coaxial to the test axis and mounted near the specimen in the piston rod. This results in high positioning repeatability and precise piston travel measurement.

HTM16020 with testControl II


  • Crush tests on crash boxes

Testing solution

  •  HTM16020 with tCII
  • Fully enclosed safety device
  • Compression fixture for high-speed testing with transverse force support
  • Testing software testXpert HTM edition

Advantages and benefits

  • Long actuator stroke of 350 mm (incl. 50 mm end cushioning on both sides). This allows for testing of crash elements with a large deformation path or tensile tests on materials with high deformation until break.
  • The solid construction of the load frame and the large column diameter of the four-column load frame minimize interfering vibrations of the frame, which negatively influence test results.
  • The compression fixture with guide columns also allows for testing of larger components. The side-mounted transverse force support protects the actuator, and allows for easy access to the test area.

Robotic testing system roboTest N for fully automated small series testing in the lab


  • Among others, automated performance of tensile, flexure or function test on autoinjectors

Key features

  •  roboTest N robotic testing system with testing machine
  • Flexible specimen magazines (different sizes)

Advantages and benefits

  • Complete integration into the ZwickRoell software environment
  • Integration into the system without robot programming knowledge
  • Testing is user-independent and therefore more reliable
  • Your own specimen magazines that, for example, are manufactured in 3D printing methods, can be integrated
  • The intuitive user interface roboTest Assist also ensures flexible use for future testing applications.
  • Compact, space-saving design, reduction of necessary operator safety measures

videoXtens 2-120 HP+

videoXtens is used for optical measurement of extension on contact-sensitive and highly elastic materials. videoXtens 2-120 HP+ is also ideal for high-precision change in width. It not only fulfills the strict requirements of ISO 527-1 Annex C for determination of the tensile modulus, but also features the possibility for a wide range of applications for high and low temperatures in the temperature chamber.

Advantages and benefits

  • Easy, standard-compliant testing: The system fully covers composite and plastics testing to ISO 527-1/2/4/5, including the determination of the tensile modulus, as well as the Poisson's ratio, in-plane shear (IPS) ±45° / tensile test to ISO 14129, and 3- or 4-point flexure tests.
  • Complete specimen in field of view: The optical extensometer videoXtens 2-120 HP+ has the complete specimen in the field of view during testing. Strain is measured up to break. Because of non-contact measurement, no damage due to the fracture energy of composite specimens is caused to the extensometer.
  • Wide temperature range: With the ZwickRoell temperature chambers, the videoXtens 2-120 HP+ satisfies the strict requirements for determining the tensile modulus to ISO 527 even in a temperature range of -80°C to 250°C. All temperature chambers have been optimally adapted to the optical extensometers. Together they form a closed system which minimizes environmental influences. Temperature control and convection in the temperature chamber are optimized so that extensometer resolution guarantees a maximum level of detail even under temperature. Even the comparatively slight influence of the side panel on the measuring system scaling is compensated for. Compensation can be switched on when in temperature chamber mode by simply clicking in the software.
  •  NEW: Change-in-width measurement: With the integrated additional camera, change-in-width measurement is now also possible. The error limits for the determination of the Poisson ration to ISO 527-1 Annex B are herewith ensured.

Clip-On 8040-1 and 7537-1

Optimum operating convenience and superb accuracy make the Clip-on series stand out. Not only is the quick and easy attachment of the extensometer ideal for testing on metals, rigid plastics and composites, the small and compact design also allows for use in narrow temperature chambers. The high accuracy is prominent. All accuracy classes 0.5 and 1 to EN ISO 9513, as well as the requirements for determination of the tensile modulus to ISO 527-1 Annex C, are fulfilled.

Advantages and benefits:

  • Quick and easy attachment due to the ergonomic one-handed operation, even with a glove
  • Locking of the initial gauge length on attachment eliminates operator influence
  • The small and compact design facilitates use even in narrow temperature chambers
  • For round specimens central alignment of the clip-on is ensured with optional prismatic counter rollers


  • The clip-on extensometers are tailored to the testing of metals, rigid plastic and composites
  • They are ideal for the closed loop strain rate control to ISO 6892-1 (2009) Method A1 on metals
  • The clip-on extensometers meet the heightened requirements for determination of the tensile modulus to ISO527-1 Annex C
  • They also fulfill accuracy class 0.5 to EN ISO 9513 up to 60% of measurement displacement, as well as accuracy class 1 to EN ISO 9513 up to 100% of measurement displacement


The multiXtens is an excellent fit for testing of rubber. Large measurement displacement values can be measured with the highest accuracy. It features a high level of operating convenience with the help of automated functions, as well as by avoiding sources of error thanks to the low-vibration and precise mounting systems. The multiXtens can be modularly extended and at the same time meets the requirements for accuracy class 0.5.

Advantages and features:

  • multiXtens meets the customer requirement for large measurement displacement ranges with high accuracy and can also be used for whipping specimens and specimens with high fracture energy for application to break.
  • The extensometer is tailored for strain control to ISO 6892-1 Method A1 and in addition meets the heightened requirements for the tensile modulus to ISO527-1 Annex C
  • The contact system is characterized by high operating comfort through automated functions such as Lo setting, attachment and detachment of sensor arms, centering and test-area measurement, and supports the operator in changing applications (tensile, compression, and flexure testing) through sensor coded, interchangeable sensor arms
  • Sources of error are reduced with low-vibration and precisely swivelable mounting systems
  • The multiXtens extensometer is modularly expandable, for example for optical and tactile change in width measurement, meets accuracy class 0.5, and is verifiably calibrated from 20 µm measurement displacement


The HIT450P is the perfect choice for impact tensile and impact bending tests on metals. Not only is cost-effectiveness guaranteed through standard-compliant and quick insertion of the specimen, and therefore high specimen throughput, but the variety of test options to Izod, Charpy, Brugger, or impact tensile tests are equally impressive. A modern touch-screen and ergonomic design provide for user-friendly and reliable handling.

Advantages and benefits:

  • Test cycle times have been reduced by centrally arranging the user elements, and the specimen remains can be removed easily from defined locations after impact
  • Izod, Charpy, Brugger, and impact tensile tests are possible with one device
  • The modern touch-screen allows for intuitive operation. The high safety requirements of ISO 13849-1 are implemented in the quality manner for which ZwickRoell is known
  • Test result plausibility check via combination of analog and digital displays
  • Fast installation and accurate calibration with ZwickRoell’s concrete base

HIT pendulum impact testers up to 50J

Together with tensile and flexure tests, Charpy impact tests are the most frequently performed mechanical tests in the polymer industry. With its new HIT pendulum impact testers ZwickRoell offers modern solutions that are ready for changes in future technology. New electronics with new functionalities ensure intuitive and workflow-based operation. Quick familiarization with user management and flexible use with or without a PC is impressive.

  • Intuitive and workflow-based right from the start! All test-related settings are grouped logically and are separated from higher-level system settings. The operator is guided through test configuration step by step. The stored test configuration can be easily exported and transferred to other devices.
  • Quick familiarization with user management: Integrated user management reduces the number of operator input options, showing only what is needed. Users see only what is important to them so they can focus on the task at hand right from the start.
  • Flexible use with or without PC: Thanks to the new, standardized operating philosophy, the user can easily switch between the device and the PC.

Xflow extrusion plastometers

Extrusion tests are a simple method of characterizing the flow properties of a plastic melted mass. Xflow extrusion plastometers feature new electronics with new functionalities. The entire operating procedure is intuitive and workflow-based, with or without PC. Integrated user management reduces the number of operator input options to a minimum. Therefore, the operator only sees what is important.

  • Intuitive and workflow-based right from the start: All test-related settings are grouped logically and are separated from higher-level system settings. The operator is guided through test configuration step by step. The stored test configuration can be easily exported and transferred to other devices.
  • Quick familiarization with user management: Integrated user management reduces the number of operator input options to a minimum. Users see only what is important to them so they can focus on the task at hand right from the start.
  • Flexible use with or without PC: Thanks to the new, standardized operating philosophy, the user can easily switch between the device and the PC.

Diamond hardness testing software

Diamond combines intuition with innovation. Image analysis is carried out using a unique self-learning algorithm that recognizes indentations even on low-contrast surfaces - in short, effortless repeatability and reproducibility for a wide variety of operators.


  • Single or multiple hardness tests to Rockwell, Vickers, and Brinell
  • Case hardening tests in separate mode

Advantages and benefits

  • The software has a self-learning algorithm that can mimic human behavior for specimens with complex surfaces. This improves repeatability and reproducibility for different operators.
  • Data, including images of the indentations can be reliably stored in files that cannot be edited prior to being exported in LIMS or other data-storage or reporting systems.
  • Existing hardness testing systems operating with the high-definition software in semi-automatic version can be upgraded to the modern and intuitive Diamond software.

New version of InspectorX testing software

With the new version of the testing software for characterization of nanomechanical properties you stay on top of things! The intuitive user interface supports the user during the non-trivial applications of a nanoindenter. The revised Help feature provides application-driven knowledge and is available in several languages. The newest functionality (such as testing of wafers) expand the range of application and make InspectorX a market leader in nanoindentation software.

Applications for the ZHN nanoindenter

  • The ZHN nanoindenter is a precise, easy-to-use device with a broad range of applications for hardness and Young’s modulus testing, scratch tests, and dynamic wear tests in the nanometer range.

Advantages and benefits of the testing software

  • Predefined test sequences and position patterns through intuitive menu icons reduce the required test preparation process
  • Simple point-and-click definition of the measuring positions in the camera image
  • Refined algorithms for determining the indenter area function and device stiffness

Manufacturer-independent modernization of dynamic testing machines and systems

With the modular retroLine modernization kits for servo-hydraulic testing systems, ZwickRoell transforms outdated testing machines and systems into state-of-the-art equipment - regardless of manufacturer. Modernization of the testing machine usually includes renewal of the measurement and control electronics, as well as the testing software. With the new testControl II electronics and the Control Cube servo controller, single- and multi-channel applications can be operated.

  • Reliable service and support for a minimum of ten years, providing long-term investment security with regard to spare-part availability and service
  • Warranty for newly installed components, as with new machines
  • Compatible with current Windows operating systems and seamless integration with your IT environment
  • Compliance with safety regulations in line with current guidelines

Obtaining future upgradeability - modernization from MOPS/DUPS to testControl II

The reasons for modernization are diverse - as for example the hot topic of Windows 7, end of support. With the outdated electronics generations MOPS/DUPS an upgrade to Windows 10 is not possible. With a modernization from the electronics generations MOPS/DUPS to testControl II service reliability and the future viability of the testing system are maintained, providing significant innovation features:

  • Precise control and high positioning accuracy broaden the application range for extremely demanding tests
  • Flexible interface possibilities facilitate the connection of the most diverse sensors
  • Reliable service and support for a minimum of ten years, providing long-term investment security with regard to spare-part availability and service
  • Compatible with current Windows operating systems and seamless integration with your IT environment

ZwickRoell Condition Monitoring

With the latest ZwickRoell machine monitoring, machine data is visualized for the user on a dashboard. All data is collected in a database and saved with a time stamp - no more lost information!
Features at a glance:

  • Display of the current machine condition including: next calibration date, overloads, hours of operation, number of tests performed, and much more
  • Information on upcoming calibrations, service, and maintenance measures
  • Electronic service check lists with editable service intervals - replaces conventional manual check lists
  • Information on accessories including their condition. Condition information for both active and inactive accessories is visualized.

Innovative solutions for high-temperature tests

Thermo-mechanical fatigue

Thermo-mechanical fatigue (TMF) is the simulation of the mechanical load as a result of the thermal expansion of the material. In a power plant (as well as in every thermal engine) this occurs every time it is started up or shut down. During startup, the temperature of all components rises from room temperature to operating temperature, which is accompanied by an expansion of the material. This expansion creates a stress in the material, which must be determined with accuracy to prevent damage of components.

Testing system

  • Patented creep testing machine Kappa 100 SS-CF
  • TMF controller for synchronization of mechanical and thermal loading
  • Induction heating and air cooling incl. temperature measurement and regulation
  • Water-cooled hydraulic grips
  • Water-cooled HT extensometer
  • testXpert III test program for TMF

Advantages and benefits

  • Simulation of material fatigue through combined mechanical and thermal loading
  • Standard system to CoP
  • Reliable test results based on precise control through the patented EM machine

Creep testing in air up to 1,500°C

Improving the effectiveness and energy efficiency of power stations and turbine technology involves subjecting the materials used in their construction to ever higher pressures and temperatures. Creep tests for materials characterization are essential for the development of new materials resistant to these high temperatures. With our Kappa series we offer you high precision,
versatile, and therefore, cost efficient creep testing machines that include the following benefits:

Testing system

  • Creep testing machine Kappa 100 DS
  • 3-zone high-temperature furnace up to 1,500°C
  • Ceramic load string up to 1,500°C for round and flat specimens
  • Non-contact extensometer laserXtens HP/TZ
  • testXpert III test program for creep testing

Advantages and benefits

  • Testing up to 1,500°C in air - as in the practical use of the material
  • 3-zone control for accurate specimen temperature
  • Measurement up to specimen break without damage to the extensometer

Fatigue and creep-fatigue testing
Fatigue and creep-fatigue crack growth testing

For the design and construction of thermal and simultaneously mechanical cyclic loaded components such as gas turbines and turbines for airplanes, reliable characteristic values for the prediction of the fatigue life and plastic deformation must be available. In thermal mechanical fatigue testing, the required material characteristics are determined through the in-phase or out-of-phase combination of cyclic thermal and mechanical loads.

Testing system

  • Patented creep testing machine Kappa 100 SS-CF
  • 3-zone furnace up to 1,200°C
  • Testing system for LCF and CF tests
  • Testing system for FCGR and CFCGR tests
  • Water-cooled HT extensometer
  • testXpert R test program for LCF, CF, FCGR and CFGR

Advantages and benefits

  • Simulation of material fatigue through variable cyclical mechanical load
  • Simulation of crack growth through variable cyclical mechanical load
  • Precise control with patented EM machine