• Blog
  • Cut Costs with the ROI Calculator for In-House Tensile Testing

Cut Costs with the ROI Calculator for In-House Tensile Testing

GET A QUOTE
Cut Costs with the ROI Calculator for In-House Tensile Testing

A major component of material testing is tensile testing, which is used to determine the strength and performance of materials. However, the financial implications of such testing are quite substantial. For example, the average cost per tensile test is approximately $155. Moreover, investing in a universal testing machine (UTM) can range from $10,000 to $160,000, depending on its capabilities. Considering these substantial expenditures, organizations should critically evaluate their testing strategies.

To better assist you, TensileMill CNC introduces the ROI calculator for an in-house tensile testing solution. This tool was created to provide a comprehensive comparison between the costs associated with outsourcing tensile testing and those incurred when conducting tests in-house. By inputting specific parameters, users can obtain a detailed financial analysis, enabling informed decision-making aimed at cost reduction and operational efficiency.

The purpose of this article is to explore why tensile test costs matter, how in-house testing compares with outsourcing, and how the calculator for in-house tensile testing works. We will also discuss who can benefit from the use of this tool and how it can be used to optimize material testing processes using data-driven decisions.

Why Tensile Testing Costs Matter

Why Tensile Testing Costs Matter

For a long time, manufacturers had no way to compare outsourcing versus in-house tensile testing. Building a dedicated lab was considered too expensive, with equipment costs and technical barriers making it unrealistic for most businesses. As a result, companies relied on third-party testing, assuming it was the only cost-effective option.

However, the industry is changing. Advances in affordable CNC tensile sample preparation machines and universal testing equipment now allow businesses to perform their own tests efficiently and at lower costs. Many companies are unaware that in-house testing is now a realistic and scalable alternative, offering significant savings and operational advantages.

The ROI calculator for in-house tensile testing helps businesses break outdated assumptions about lab costs. With this tool, companies can quickly calculate their own savings, proving that in-house testing can be financially smarter than outsourcing. For those who prefer expert guidance, we can even prepare a full presentation—so you do not need to do anything yourself.

The Financial Impact of Outsourcing Tensile Testing

Outsourcing tensile testing has hidden costs beyond the per-test fee. The price per test can range from $55 to $280 per sample, but shipping, lead times, and delayed production schedules further increase expenses. Companies often overlook how material holding costs and external lab timelines affect efficiency.

With more affordable equipment now available, outsourcing is no longer the only option. Businesses can now take control of their own testing process, avoiding logistical challenges and unnecessary expenses.

Tensile Testing Equipment

Investing in In-House Tensile Testing Equipment

Previously, in-house tensile testing was reserved for large-scale operations due to high equipment costs. Now, with compact and cost-effective testing solutions, companies of all sizes can set up their own labs. Entry-level machines start at $2,500 to $6,000, while advanced UTMs range from $10,000 to $160,000, offering a more accessible path to in-house testing.

The latest devices require minimal operator training, making it easier to integrate tensile testing without disrupting production workflows. The result is faster test cycles, better control, and long-term savings.

Balancing Costs and Benefits

Until now, many companies assumed in-house labs were too expensive, but with new technology, that is no longer the case. The ROI calculator for in-house tensile testing allows businesses to run their own cost analysis and see exactly how much they can save.

The world is changing, and testing changes with it. Companies that implement cost-effective solutions will not only reduce expenses but also gain a competitive advantage in speed, efficiency, and operational control.

How the ROI Calculator for In-House Tensile Testing Works

How the ROI Calculator for In-House Tensile Testing Works

Using the calculator for in-house tensile testing solutions allows manufacturers and laboratories to accurately compare outsourcing costs to in-house sample preparation and testing. By entering key operational parameters, businesses can identify cost savings, improve financial planning, and optimize material testing workflows.

Step 1: Enter Key Testing Parameters

To generate a detailed cost analysis, users enter specific details about their tensile testing process:

  • Location Selection – Choose between the United States, Canada, Europe, or Other regions to confirm that cost estimates align with regional market trends.
  • Sample Type – Select one or multiple tensile sample types: flat, round, or impact specimens.
  • Sample Cost Inputs – The default values are:
    • Flat sample cost: $240 per sample.
    • Round sample cost: $200 per sample.
    • Impact sample cost: $225 per sample.
    • These values can be adjusted based on actual business expenses.
  • Testing Scope – Calculate the cost of sample preparation only or both sample preparation and tensile testing.
  • Batch Size – Input the number of samples tested per batch for each sample type.
Key Testing Parameters for Tensile Testing ROI Calculator

Step 2: Include Additional Cost and Operational Factors

Beyond sample costs, the calculator also accounts for logistics, growth projections, and lead times:

  • Shipping Cost Per Batch – The default value is $50 per batch, which can be modified according to real-world shipping expenses.
  • Batch Shipment Frequency – Users select shipment intervals, such as weekly, to reflect outsourcing schedules.
  • Annual Growth Rate – The expected cost increase per year is set at 10%, helping businesses predict future expenses.
  • Turnaround Time Per Batch – The default value is 14 days, showing how outsourcing testing affects production schedules.
Key Testing Parameters for Tensile Testing ROI Calculator 2

Step 3: Generate a Cost Comparison Report

Once all data is entered, the calculator processes the information and provides a detailed financial projection. As an example, here are some numbers:

Generate a Cost Comparison Report in ROI Calculator for Tensile Testing Solution

As part of the report, businesses will also be able to view graphical cost projections over time:

Projected Costs and ROI Using In-House Tensile Testing Equiment

Who Benefits from the Calculator for In-House Tensile Testing Solutions?

The ROI calculator for an in-house tensile testing solution is a valuable tool for quality control, manufacturing, financial decision-making, and research and development professionals. Businesses can assess costs, optimize operational efficiency, and make informed investment decisions by comparing outsourcing and in-house testing. Take a look at how different industries and roles can benefit from our calculator.

Quality Control and Testing Laboratories

For quality control and testing laboratories, frequent outsourcing of tensile testing can create delays, increase expenses, and introduce variability. Having a way to calculate the financial impact of in-house testing allows laboratories to evaluate whether investing in their own CNC tensile sample preparation machines is a better long-term solution. By reducing dependency on external testing providers, laboratories can accelerate testing cycles, improve accuracy, and maintain tighter control over material evaluation processes.

Manufacturing and Engineering Companies

Manufacturing and engineering companies in industries such as aerospace, automotive, construction, and metallurgy often require the testing of tensile strength as a routine part of product validation and quality assurance. The ability to quantify the cost of outsourcing versus in-house testing enables them to determine whether bringing sample preparation and tensile testing in-house will reduce overall expenses while maintaining operational efficiency. By shifting to internally managed testing, companies can avoid unexpected outsourcing costs, minimize lead times, and improve workflow integration. For businesses experiencing growth, the calculator also allows them to project long-term cost savings as their testing needs increase over time.

Financial Decision-Makers and Procurement Teams

From a financial and procurement perspective, investing in tensile testing equipment requires justification based on measurable cost savings and return on investment. The calculator provides a structured financial overview, allowing decision-makers to assess when in-house testing becomes economically reasonable. By analyzing both immediate cost reductions and long-term financial benefits, procurement teams can make strategic purchasing decisions that align with company goals and budget allocations.

Research and Development (R&D) Departments

Research and development departments benefit significantly from in-house tensile testing capabilities. Companies focused on material innovation and product development often need to test prototypes and novel materials under different conditions. Outsourcing these tests can slow down development timelines and introduce confidentiality concerns. The calculator helps quantify the cost-effectiveness of internal testing resources. Thus, making it certain that companies maintain faster R&D cycles, better intellectual property security, and greater flexibility in material testing.

Regarding industry or business size, the calculator for an in-house tensile testing solution can assist any organization looking to optimize testing expenses without compromising accuracy or efficiency. With this tool, businesses can analyze testing expenditures, predict long-term savings, and gain a better understanding of how in-house tensile testing equipment can contribute to overall cost reduction and operational efficiency.

Tensile Testing Laboratory

Maximizing Cost Efficiency in Tensile Testing

Testing for tensile strength is an integral component of material evaluation, but the associated costs can be quite high, especially for businesses that rely on frequent testing. By comparing outsourcing expenses with in-house testing investments, the ROI calculator for an in-house tensile testing solution provides a clear financial roadmap for laboratories, manufacturers, and decision-makers. Businesses can assess sample preparation costs, shipping expenses, and long-term savings projections, helping them determine whether investing in CNC tensile sample preparation equipment is the right move.

With the ability to reduce turnaround times, avoid third-party expenses, and improve operational efficiency, in-house tensile tests can be a cost-effective solution for companies aiming for increased control over material evaluation. The calculator serves as a practical tool for informed decision-making, allowing businesses to optimize budgets, increase testing efficiency, and optimize quality assurance processes.

If you require assistance or additional information, please do not hesitate to contact us or request an online quote. Our goal is to help you obtain quality tensile testing at a reasonable price.

Back to all blogs

Which ISO Standards Should Tensile Test Equipment Meet For Reliable, Audit-Ready Results?

For a UTM and its accessories, look for force verification to ISO 7500-1, extensometer calibration to ISO 9513, and calibration work performed by an ISO/IEC 17025 accredited provider. Pair these with the applicable method standard, such as ISO 6892-1 for metals or ISO 527-1 for plastics, so machine capability and procedure align. In practice, request certificates that list instrument serial numbers, measurement uncertainty, traceability, and environmental conditions. Select an accuracy class that matches your tolerance, commonly class 1 or class 0.5. Force verification should span at least five points across the working range. Example sets include 2,250 lbf, 5,600 lbf, 11,200 lbf, 22,500 lbf, and 44,900 lbf (10 kN, 25 kN, 50 kN, 100 kN, 200 kN), scaled to frame capacity. Many labs follow a 12-month interval, then adjust based on historical drift. Day to day, operators zero the load cell and extensometer, check grip face condition for wear, and confirm rate control per the selected standard. Keep ambient near 73°F ±9°F (23°C ±5°C) when the method calls for room-temperature testing. Store the latest certificates at the workstation to speed audits and support troubleshooting. If you need accredited calibration or certificates, you can review services on the Certification For Testing Equipment page.

What Practical Benefits Do ISO-Certified Tensile Testing Systems Deliver For QC Labs?

Certified systems bring traceable force and strain accuracy classes, so acceptance limits mean what they say. With ISO 7500-1 Class 1 or 0.5 load verification and ISO 9513 calibrated extensometry, repeat tests drop, multi-site data lines up, and audit trails stay clean. Results are easier to compare across plants and suppliers working to ISO 6892-1 for metals or ISO 527-1 for plastics. Daily work becomes more repeatable. Operators load the specimen, check zero, and run method files that hold crosshead speed at setpoints such as 0.2 in/min (5.08 mm/min) for metals pre-yield steps or 20 in/min (508 mm/min) for plastics screening. Class 1 accuracy keeps force within ±1% of reading, while Class 0.5 tightens that to ±0.5%, which helps when materials sit near specification edges. A quick routine helps: confirm the calibration sticker is within the 12-month interval, verify alignment so bending stays within ASTM E1012 limits, and check gauge length at 2.00 in (50.8 mm) before attaching the extensometer. Save certificates and machine logs with serial numbers and time stamps, so any outlier can be traced without halting production. If you would like to review accreditation scope and calibration methods, you can read more on the Certification for Testing Equipment page.

What Does ISO Certification Actually Cover on a Tensile Testing System?

ISO certification addresses three layers of the tensile setup. Force verification per ISO 7500-1 covers the frame, load cell, and controller, with accuracy classified at the reading, often Class 1 or Class 0.5. Strain measurement is covered by ISO 9513 so extensometers track strain within their class across the stated gauge length. The calibration and reporting are performed under an ISO/IEC 17025-accredited scope, with traceable certificates and documented uncertainty. On the floor, this changes how operators prepare and defend results. During a force check, a technician loads several points, for example 10,000 lbf (44.5 kN), and confirms the readings stay within the allowed percentage across the range. Crosshead speed can be verified by timing 0.50 in/min (12.7 mm/min) over a 2.0 in (50 mm) travel using an independent reference. Alignment records, software revision control, and accessory serial numbers round out the audit trail. To confirm coverage, request current ISO 7500-1 and ISO 9513 certificates tied to machine and accessory serials, plus the ISO/IEC 17025 scope and calibration dates. Keep these with your test methods so QA can quickly match data sets to valid certificates during audits. You can review scope details, calibration options, and sample documentation on the Certification for Testing Equipment page.

What Does ISO 7500-1 Class 1 vs Class 0.5 Mean for Tensile Tester Accuracy?

ISO 7500-1 defines the allowable force error of the machine as a percent of the indicated load. Class 1 allows ±1% of reading, while Class 0.5 allows ±0.5%. At 20,000 lbf (89 kN), Class 1 permits ±200 lbf (±0.89 kN) error and Class 0.5 permits ±100 lbf (±0.44 kN). That difference affects yield determination, modulus slope quality, and Cpk targets in aerospace or high-spec manufacturing. During certification, a lab verifies force at several points across the working range, typically 20% to 100% of capacity, using traceable proving devices. Stable conditions matter, such as about 68 F (20 C) and adequate electronics warm-up. Operators select a load cell so most tests fall between 10% and 90% of its range to lower uncertainty. Rate control and strain measurement should also be checked against the applicable method, such as ISO 6892-1 metals or ISO 527 plastics, and extensometers calibrated per ISO 9513. Alignment checks per ASTM E1012 help reduce bending; many NADCAP programs target ≤5% bending strain ratio. Choose Class 0.5 for tight tolerances or low elongation alloys. Class 1 fits routine QC where wider limits are acceptable. Pair results with ISO/IEC 17025 documentation and a 12-month calibration interval, or shorter with heavy usage or load cell changes. If you need accredited calibration to ISO 7500-1 and ISO 9513, you can review details on the Certification for Testing Equipment page.

What Does ISO Certification Cover On A Tensile Tester And How Do I Verify It?

ISO certification on a tensile machine confirms that force measurement and test methods are checked against defined standards. For metals at room temperature, ISO 6892-1 governs procedure and data reporting. For plastics, ISO 527-1 sets geometry and rate controls. Force accuracy is verified to ISO 7500-1 with traceability to national metrology, typically at a 12-month interval, and the certificate links to the machine’s serial number. This foundation supports repeatable tensile strength, yield, and elongation results. Verification in practice starts with the ISO 7500-1 certificate. Check the accuracy class, for example Class 1 ±1% or Class 0.5 ±0.5% of reading across the listed range. Confirm verification points bracket your workload, such as 2,000 lbf to 10,000 lbf (8.9 kN to 44.5 kN) on a 22 kip (100 kN) frame. Review the control software for correct method settings per ISO 6892-1 or ISO 527-1, including gauge length inputs like 2 in (50 mm) and the specified rate or strain control mode. When strain is critical, use an extensometer calibrated to ISO 9513 Class 1 or better with suitable travel, for example 1 in (25 mm). If you would like to review calibration and accreditation details, you can read more on the Certification for Testing Equipment page.

Contact us today to request a quote for your tensile sample preparation equipment

GET A QUOTE
TensileMill CNC Inc. © 2025