Build to Print | Test & Measurement | Test System Replication

Test System Replication / Build-To-Print

Averna’s Build-to-Print services replicate your test and measurement systems with total fidelity and adapt them to your operational reality. We provide end-to-end support, including station optimization and full lifecycle tracking, so you never lose control over performance or quality.

The Highest Quality & the Lowest Risk With our Test Systems

Need to manufacture test stations? For more than 15 years we have sourced, assembled, tested and shipped fleets of robust, cost-effective solutions. We produce them at our high-volume facilities and deploy them around the world. Our fast replication and support services granted by our test engineering experts can boost your product quality, speed up time to market, and increase your competitive edge.

Proven processes

At Averna, we adhere to rigorous verification and validation protocols at every stage of the test station replication process. With decades of experience and global expertise, we ensure that your test systems are built with consistency. Trusted across sectors like life sciences, in automotive test solutions, consumer electronics testing and more, our proven methods deliver repeatable performance at scale, worldwide.
Fully equipped facilities

Our highly secure, efficient manufacturing facilities are equipped with cutting-edge technology to handle complex, large-scale production runs. With production capabilities across multiple global sites, we ensure timely delivery and seamless integration for your test systems — no matter where you are in the world.

Want to see how we do it? Let's book you a tour and learn how we can accelerate your test station manufacturing with precision!
Automated Handling & Integration

To be thoroughly tested many products need to be lifted, rotated, moved and manipulated. We offer substantial integration expertise in robotic integration service and more.

Inside Our Build-to-Print Process: Optimized Test Station Manufacturing

Sourcing: Best Quality, Pricing and Delivery

We start with your test-station design or collaborate with you to design it as part of our broader testing and measurement solutions tailored to your product architecture. Next, we launch our bill-of-material and material planning processes.

Extensive global network of suppliers and partners
Technology-agnostic/vendor-neutral approach
BOM definition and analysis
ECR management
Alternate supplier identification
Material planning and procurement (MRP)
Parts inspection
Supplier scorecard rating

Planning: Timely and Flawless Execution

We optimize our floor layout and tooling processes to streamline the assembly routing and flow.

Production floor layout and tooling
Capacity and MRP simulations
JIT, Kanban and BOM integration

Assembly: Full NPI & Mass Production Coverage

While our highly skilled technicians quickly assemble your stations, we remain in close contact providing regular updates, key performance indicators and action items.

NPI activities for scalability
Visual work/assembly instructions
Documentation, routing, tooling
Talk time studies and ramp-up plans
Software integration
Closed loop feedback/continuous improvement
Regular client communication and KPIs

Testing: Thorough Inspection

Once assembled, each station undergoes a battery of visual, manual and automated inspections.

Quality checklists
Visual inspections and self-inspections
Test-plan execution
Test data capture and analysis
Final inspections and photographs
ISO compliant, ITAR, Controlled Goods Program

Deployment of Manufacturing Test Stations: Streamlined Delivery and Setup

Upon final inspection by an Averna Quality Control Engineer, we securely crate the stations for safe shipping to your facility or contract manufacturer anywhere in the world.

Crating design and fabrication
Brokerage and freight services
Contract manufacturer (CM) integration
Factory acceptance tests (FAT)
Site acceptance tests (SAT)
Training of local resources

Support: Station Optimization

Our coverage can extend well beyond delivery and deployment – we offer services for preventive and corrective maintenance, spare parts storage, upgrades and more.

Production ramp-up
Preventive/corrective maintenance
Test asset management and utilization
Spare parts management
Test station storage, repairs and upgrades

Leverage Our Manufacturing and Supply-Chain Expertise

Whether you need a single test bench or a global rollout of identical systems, we handle complexity at scale. Our facilities are built for high-mix, high-precision production. We manage documentation, compliance, procurement, and logistics — all under one roof.

Our edge? Full visibility across the supply chain and continuous feedback loops with your teams. It’s not just build-to-print. It’s build-to-perform.

In the automotive sector, an EV technology innovator partnered with Averna to industrialize and deploy a new generation of validation test systems based on internally defined test designs. The objective was to replicate and scale these systems quickly to support R&D acceleration and certification requirements.

Build-to-print execution enabling rapid replication of multiple custom test systems, with engineering support to resolve design constraints and ensure manufacturability at scale
Agile deployment process combining fast sourcing, redesign iterations and close collaboration, ensuring continuity despite supply chain and integration challenges

This approach transforms custom test designs into scalable validation platforms, allowing teams to accelerate lab deployment while maintaining consistency, quality and schedule control across multiple stations.

< 6 weeks to first delivery

~20 Test Stations

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Ready to Replicate your Test Systems

Take the uncertainty and risk out of test station manufacturing. Whether you're scaling up, replicating existing assets or starting a new deployment, Averna guarantees a smooth, quality-driven process.

Talk to one of our Build-to-Print experts to find out why leading global organizations count on us for flexible and cost-effective test stations.