The Test Before the Test: How New Simulators Build Safer, Smarter Products

TEWKSBURY, MA – June 23, 2026 – Every time you fly, drive a modern car, or rely on a piece of critical industrial equipment, you are placing your trust in millions of lines of code and a web of intricate electronics. Behind that trust lies an invisible world of rigorous testing, a world that just took a significant leap forward. Today, Pickering Interfaces, a key supplier of modular testing solutions, announced a new suite of analog output modules that redefine the realism and efficiency of how we validate the complex products that shape our lives.

This isn't just another product launch. It's a strategic response to the ever-increasing complexity of our technology. As vehicles, aircraft, and medical devices become more autonomous and interconnected, the methods used to test them must evolve beyond simple checks. They must be able to simulate the messy, unpredictable nature of reality itself. Pickering's new modules are engineered to do precisely that, providing a more robust bridge between the digital design board and the physical world.

A New Frontier of Digital Realism

At the heart of the announcement are three new families of PXI/PXIe modules—a standardized, modular platform for building compact test systems. These include multi-channel waveform generators, precision digital-to-analog converter (DAC) outputs, and high-density thermocouple simulators. In essence, they allow engineers to create a high-fidelity 'matrix' for a product's electronic brain, simulating the real-world signals it would receive from sensors during operation.

Imagine testing the electronic control unit (ECU) of an electric vehicle. Instead of connecting it to a physical battery pack and drivetrain, Hardware-in-the-Loop (HIL) simulation uses these modules to 'feed' the ECU the exact voltage, current, and temperature signals it would see on the road. The new waveform generators, with up to 32 independent channels, can simulate vibrations from a bumpy road via accelerometer signals. The thermocouple simulators can replicate precise temperature fluctuations in a battery pack, down to the microvolt level. The DAC modules can provide the precise power signals needed to drive other components.

"These new analog output modules expand Pickering's ability to support realistic signal and sensor simulation across functional test and HIL applications," said Stephen Jenkins, the company's Simulation Product Manager. "They deliver high channel density, precise performance, and dependable long-term support in modular PXI/PXIe platforms."

This level of realism is crucial. It allows for exhaustive testing of software and hardware interactions under a vast array of conditions—conditions that would be too expensive, time-consuming, or dangerous to replicate physically. It enables engineers to find and fix bugs earlier, leading to more robust and reliable end products.

Smaller Footprint, Bigger Impact: Redefining Test Efficiency

The strategic genius of Pickering's new offerings lies not only in their performance but also in their design philosophy. The test and measurement industry is in the midst of a powerful shift towards modularity, a market projected to grow at a nearly 10% compound annual rate to over $6 billion by 2030. The driving force is a demand for test systems that are scalable, flexible, and efficient.

By packing an unprecedented number of channels into a single PXI/PXIe slot—up to 32 in the case of the waveform generator and thermocouple simulator—Pickering directly addresses this demand. In practical terms, this means test engineers can build more capable systems in smaller enclosures. This reduces the physical footprint in crowded labs, lowers power consumption, and simplifies system architecture. It's a clear example of how thoughtful engineering delivers lasting value, reducing the total cost of ownership for test infrastructure that can represent millions of dollars in investment.

Furthermore, by committing to the open PXI standard and guaranteeing long-term product support, the company directly confronts the pervasive threat of obsolescence. For industries like aerospace and defense, where product lifecycles are measured in decades, this assurance is not a luxury; it is a fundamental requirement.

Engineering for Failure: The Critical Role of Fault Simulation

Perhaps the most significant innovation, and the one with the most direct impact on public safety, is the deep integration of fault simulation capabilities. A truly robust system isn't just one that works perfectly under ideal conditions; it's one that behaves predictably and safely when things go wrong.

The new DAC and thermocouple simulator modules allow engineers to do more than just simulate normal operation. They can actively inject failures into the system. With software control, a test engineer can simulate an open-circuit—the digital equivalent of a wire breaking or a sensor connection coming loose. They can then verify that the system's embedded controller identifies the fault and enters a safe state, rather than operating on erroneous data.

This capability is transformative for developing safety-critical systems. For an automotive engineer, it means being able to confirm that a car's stability control system responds correctly if a wheel speed sensor fails. For an aerospace engineer, it means ensuring a flight control computer can handle the loss of a temperature probe without compromising control. By making it easier to test for failure, these modules empower companies to build fundamentally safer products.

A Strategic Play in a Competitive Field

In a market where giants like National Instruments have long set the pace, Pickering's strategy appears to be one of targeted, high-value specialization. Rather than engaging in a head-to-head battle on every specification, the company is doubling down on the specific needs of the HIL and functional test communities. The focus on extreme channel density, integrated fault injection, and specialized sensor simulation carves out a powerful niche.

This is a recognition that the future of testing is not just about raw speed or bandwidth, but about the quality and realism of the simulation. The modules are backed by extensive software support, including drivers and APIs for all major engineering languages like Python, MATLAB, and LabVIEW. This ensures they can be easily integrated into the automated, software-defined workflows that are becoming standard in modern R&D, including the Continuous Integration/Continuous Delivery (CI/CD) pipelines that accelerate development cycles.

By providing the tools to build more realistic virtual worlds for testing, Pickering is enabling a new level of confidence in the complex systems that underpin our modern society. It is a quiet but profound change, ensuring the technology of tomorrow is not just more capable, but also more dependable.