Product Testing Myths — Straight from the Lab

When it comes to product testing, a lot of assumptions float around, especially among the manufacturing industry. As a certification body, we often see the same misconceptions repeated by companies preparing to launch a new product or working toward compliance. To set the record straight, we turned to our technical team. 

5 Most Common Myths About Product Testing

Here are five of the most common myths about product testing, and the reality behind each one.

1. If a product passes testing once, it will always pass.

It’s a comforting idea, but not a reliable one. A product that passes testing once isn’t guaranteed to pass again, even if it’s the same model. Here’s why:

• Two different samples of the same model can have a certain amount of variability between them.
• Certain product defects will:
  • Only appear in a random percentage of samples.
  • Result from unnoticed changes to a production process.
  • Emerge only after a certain amount of time or use.
• Even with identical test items, there may only be a certain probability of failure. The same product tested twice can have different outcomes.
• All tests involve a degree of randomness:
  • Some tests are highly repeatable, like an operating temperature test on a well-made power supply.
  • Others, such as fire resistance or flame spread tests, involve uncontrollable factors like airflow or environmental conditions, which can influence the result even for identical samples. That’s why many standards require testing multiple samples and averaging results.
  • Testing variations between labs or technicians can also affect results, even within acceptable tolerances. For instance, a test chamber that’s 4°C different between labs could mean a pass in one case and a fail in another, despite both meeting the standard.

Manufacturers should aim to exceed the minimum testing thresholds, not just meet them. That margin helps ensure continued compliance over time and consistent product performance.

2. Standards ensure a product is completely safe and high quality.

Standards serve an important role, but they’re not a guarantee of complete safety or quality. Instead, they set a minimum acceptable level of compliance that balances the needs of three key stakeholders:

• Manufacturers aim to minimize costs while remaining competitive, which sometimes means reducing complexity and performance to the lowest acceptable level.
• Consumers want safe, high-quality, low-cost products, but preferences vary.
• Regulators aim to reduce risks of injury, property damage, and fatalities, while maintaining realistic expectations for reliability.

Even certified products can carry risks:

• Some products have inherent hazards that are too difficult or expensive to eliminate. Labels or maintenance schedules may help, but the risks remain.
• Most products are tested when they’re fresh from the factory:
  • Wear and tear can degrade components like cable insulation or hoses.
  • Repairs and modifications can introduce safety issues.
  • Parts may fail naturally over time.
• Standards don’t test for everything. Some hazards might not be covered at all.
• A product certified for one environment may be unsafe in another:
  • A certified contactor could cause a fire in a hazardous area like a sawmill if not evaluated for that use.
  • Equipment approved for indoor use could become dangerous when used outdoors.

Also, certification doesn’t necessarily equal quality:

• Many standards focus solely on safety and don’t evaluate:
  • Usability or interface design.
  • Feature sets.
  • Performance beyond safety minimums.

Certification confirms compliance with a baseline, not that a product is free from all risk or is top-tier in quality.

Standards focus on generic safety and reliability factors within a category of products. To ensure readiness, manufacturers should go beyond standard compliance:

• Accelerated life-cycle testing to identify weak points before failures happen in the field.
• User acceptance testing to see how consumers actually interact with the product, which is often different from what designers anticipate.
• In-situ field testing to observe real-world usage and identify unexpected issues.
• Assembly line testing to catch production defects before products are shipped.

Standards are only one piece of the puzzle. Real-world readiness comes from a broader testing strategy tailored to how and where the product will be used.

4. Software and engineering analysis can simulate any physical test.

Engineering analysis is an essential tool, but it’s not a substitute for physical testing.

• In some cases, simulation is preferred or even required (e.g. thermal modeling of windows).
• However, physical testing still plays a critical role:
  • Analyses rely on theoretical models. These models differ, sometimes significantly, from the real product, which can lead to inaccurate predictions.
  • Complex interactions (materials, geometries, fluid dynamics, etc.) are often too difficult to simulate accurately.
  • Analyses involve millions of micro-decisions, any of which can introduce errors that are hard to catch.

Simulation is a great complement to testing, especially in early development, but it should never fully replace putting the actual product to the test.

5. Testing only needs to be done before launch.

Pre-launch testing is important, but not enough.

Relying solely on final testing can lead to costly redesigns, delays, or worse, product recalls. It’s more efficient and effective to include testing throughout development:

• Early-stage R&D testing helps catch problems while they’re still inexpensive to fix.
• Iterative testing supports smarter design decisions and faster progress.

Think of testing as a continuous process, not a checkbox. It’s a tool to guide your design and protect your bottom line.

Final Thoughts

Product testing is about more than passing a checklist or getting a stamp of approval. It’s about understanding how your product behaves, not just in the lab, but in the real world, over time, in the hands of your users.

By debunking these common myths, our goal is to help manufacturers take a more informed, proactive, and strategic approach to testing. Because a well-tested product isn’t just safer. It’s smarter, stronger, and more trusted by customers.