Development of a Test Rig for Detecting Fatigue Cracks in a Plastic Component of a Medical Device via Acoustic Signal Acquisitions

This work presents the design and implementation of a mechanical test bench developed for the comparative evaluation of three configurations of a mechanical biomedical device: the reference version and two optimized alternatives aimed at improving long-term reliability and functional performance. The test bench performs mechanical fatigue testing under controlled and repeatable conditions, simulating the cyclic loads typical of real-world operation. A key innovation of this system is the integration of a non-invasive acoustic acquisition module, which continuously monitors the dynamic behavior of the device during testing. The analysis of acoustic signals allows for the early detection of wear, looseness, deformation, and the onset of structural defects, providing valuable insight into the device’s mechanical health without altering its configuration. This study also details the engineering design of the control system, emphasizing both hardware integration and software architecture supporting real-time signal processing. Experimental results demonstrate that acoustic analysis represents an effective non-destructive approach for evaluating the endurance and reliability of compact plastic biomedical devices. The proposed methodology contributes to more accurate service life estimation, supports product validation, and promotes continuous improvements in the safety and quality of mechanical systems used in biomedical applications.