Old test equipment is becoming difficult to maintain and upgrade. Engineering teams want better ways to improve test coverage.
They also want to enhance diagnostics and speed up test cycles. But one factor continues to dominate decision-making: cost. Are modern test technologies more cost-effective than traditional solutions like In-Circuit Test (ICT)?
As embedded systems grow more complex, the need for smarter test strategies becomes urgent. Engineers are under pressure to maintain test integrity while reducing costs and keeping pace with faster production cycles. The challenge is clear: how do you test thoroughly when physical access is disappearing?
The Disappearing Test Access Challenge
Test access is steadily disappearing because of the growing design complexity and tighter integration. This challenge is well known in the test engineering community and often discussed in industry forums.
The trend of higher circuit board densities and faster I/O protocols is growing. For example, PCIe Gen5 operates at 32GT/s. This makes it difficult to place physical test points.
As a result, traditional ICT methods are no longer sufficient. Engineers need test equipment that can adapt to these constraints without compromising coverage or diagnostics.
Why ICT Is No Longer Enough
ICT has served the industry well, but it’s no longer equipped to handle the realities of modern electronics. As physical access disappears, engineers need solutions that are flexible, scalable, and software driven. Non-Intrusive Board Test (NBT) technologies offer a compelling alternative.
ScanWorks® provides a unified platform for NBT strategies like boundary scan, processor-controlled test, and advanced testing tools. These tools eliminate the need for physical access while improving coverage and diagnostics. They also reduce costs across capital investment, fixturing, and lifecycle maintenance.
Unlike traditional ICT, which depends heavily on hardware and fixtures, NBT leverages software as its primary implementation method. This makes it easier to deploy across global sites, scale with production, and adapt to design changes.
Capital Cost Savings
Let’s consider a typical new production line. ICT is often used for:
- Unpowered testing to detect shorts and opens
- Discrete component value measurement
- Powered testing
When component values are verified off-reel and powered testing is managed through NBT and functional test, ICT becomes unnecessary and can be replaced by a Boundary Scan Test (BST), processor-controlled test (PCT), and built in self-test (BIST).
Compared to traditional intrusive testing methods, NBT technologies offer greater flexibility, are driven by software, and are significantly more economical. While conventional In-Circuit Test systems can start at over $250,000 and may exceed $1 million over their lifecycle, a PC-based NBT setup can be integrated into a production line for under $25,000—roughly one-tenth the cost of an ICT system. Additionally, NBT eliminates the need for intricate test fixtures, which are not only costly to manufacture and maintain but also require replacement with each design modification.
Fixturing Cost Reductions
Fixture costs vary widely, typically ranging from $3 to $10 per node. For a board with 4,000 nodes, and assuming NBT eliminates the need for 75% of those test points, the savings are substantial:
- 75% × 4,000 nodes × $7/node = $21,000 saved per fixture
These savings scale quickly across multiple designs and production lines. Reducing fixture complexity also shortens development time and lowers the risk of errors during test setup.
Lifecycle Cost Advantages
NBT strategies offer long-term benefits that go beyond initial savings. These include:
- Reduced hardware maintenance
- Instant global deployment via floating licenses
- Lower fixture wear and fewer re-spins
- Easier deployment at repair sites
- Lower test and fixture development costs
- Enhanced diagnostics and faster test cycles
Software-based test strategies are easier to update and maintain. They also support remote collaboration, which is increasingly important for distributed teams. While these savings vary by product, they often reach tens of thousands of dollars per line.
Improved Test Integrity and Coverage
One of the most compelling reasons to adopt NBT is the improvement in test integrity. Traditional ICT can struggle to detect subtle faults in high-speed designs. NBT technologies, especially when combined with functional test, offer deeper visibility into system behavior.
ScanWorks enables engineers to validate signal integrity, verify firmware execution, and monitor system-level interactions—all without relying on physical access. This leads to higher fault coverage and more actionable diagnostics.
Flexibility for Modern Production Environments
Modern production environments demand flexibility. Whether you’re launching a new product line or updating an existing one, your test strategy needs to adapt quickly. ScanWorks and other NBT tools are purpose-built to meet this challenge.
Because NBT runs on software, teams can deploy it instantly across multiple sites. Engineers can reuse test assets, share licenses, and respond to design changes without waiting for new fixtures or hardware. This agility helps teams stay ahead of production schedules and reduce time-to-market.
The Bottom Line
Transitioning to NBT can save more than $200,000 per new production line. With ScanWorks stations available for $25,000 or less, the return on investment is clear. These savings come without sacrificing test integrity, coverage, or diagnostic depth.
ScanWorks helps you move forward with confidence—equipping your team with the tools they need to test smarter, faster, and more cost-effectively.
