For over 30 years, MK Test Systems has been at the forefront of designing and supplying high-performance electrical testing equipment for industries where reliability is critical. As wiring and harness systems grow more complex, the need for efficient and accurate testing solutions has become increasingly important.
One of the most significant industry shifts in recent years has been the widespread adoption of hybrid copper-fibre cables, particularly in aerospace, defence, telecommunications, and transportation. These cables combine copper’s power transmission capabilities with the high-speed data transfer of fibre optics, making them essential to modern electrical and communication systems.
Testing these hybrid cables, however, has presented a challenge. Until now, manufacturers have been required to use separate test systems for electrical and optical elements, adding cost, complexity, and delays to production and maintenance processes. In response, MK Test Systems, in collaboration with AVoptics, is developing a hybrid electrical-optical test system—an integrated solution that can test both copper and fibre elements efficiently and accurately.
The need for such a system is driven by the increasing presence of hybrid cables across industries and the challenges they introduce. Hybrid cables require two distinct testing technologies—one for electrical conductivity and another for optical performance. By integrating these into a single, commercial off-the-shelf (COTS) solution, the new system aims to simplify the testing process.
Nick Baker, New Product Development Manager at MK Test Systems, explains: “With a continued increase in the use of hybrid fibre/copper harnesses in aerospace, a single COTS solution would be ideal for both manufacturing and aftermarket testing requirements.”
By leveraging MK Test Systems’ expertise in electrical testing alongside AVoptics’ deep knowledge of fibre optic technologies, the collaboration is focused on creating a solution that benefits manufacturers across the entire supply chain, from component validation to final installation and in-service maintenance.
The hybrid test system is designed to support multiple stages of production and servicing:
- Component Manufacturing – Before hybrid cables are assembled, individual copper and fibre elements require testing. The system allows manufacturers to validate both types of components in a single test, ensuring quality standards are met early in the process.
- Cable and Harness Assembly – During assembly, real-time testing ensures that terminations, splicing, and connections are correctly completed, reducing rework and identifying faults early.
- OEM Integration and System Installation – Many manufacturers integrate hybrid cables into larger systems, such as aircraft, rail networks, and electric vehicles. A single test system that can assess both electrical and fibre elements ensures these cables function correctly before installation, reducing system failure risks.
- Field Maintenance and Repair – Hybrid cables are increasingly deployed in challenging maintenance environments, such as defence, offshore energy, and aerospace. A test system capable of diagnosing faults in both copper and fibre elements on-site enables faster repairs and reduced downtime.
- Aftermarket Testing and Compliance – For industries with strict safety and performance regulations, ongoing compliance testing is crucial. The hybrid test system simplifies compliance checks, ensuring cables remain reliable throughout their operational lifespan.
By integrating electrical and optical testing into a single system, manufacturers stand to benefit in several ways:
- Reduced testing time – A single test setup eliminates unnecessary delays.
- Improved accuracy – Minimizing discrepancies between separate testing methods.
- Lower costs – One system performs the role of two, reducing equipment and training expenses.
- Increased scalability – The system can be applied across different production and servicing stages.
MK Test Systems will be demonstrating the hybrid test system at the Electrical Wire Processing Technology Expo (EWPTE) from May 6-8, 2025, at the Baird Center in Milwaukee. Attendees will have the opportunity to see the system in action and discuss how it can support their operations.
As hybrid cables continue to shape modern electrical and data systems, testing technology must evolve alongside them. MK Test Systems’ new hybrid test system is designed to meet this demand, ensuring manufacturers can deliver reliable, high-quality products while streamlining their testing processes. More details on the system’s capabilities will be shared as development progresses.
