Instytut Badań i Rozwoju Motoryzacji Bosmal Sp. z o.o.
- ul. Sarni Stok 93, 43-300 Bielsko-Biała, Poland
- 33 81 30 539
- bosmal@bosmal.com.pl
- www.bosmal.com.pl
Description
BOSMAL – Technology Partner for the Defence Industry
The development of modern defence systems requires the integration of design, manufacturing and testing capabilities.
BOSMAL brings all these areas together within a single organisation, supporting manufacturers and suppliers in the defence sector throughout the successive stages of development and validation of new solutions.
For over 50 years, we have been delivering advanced engineering projects for industry. Our interdisciplinary team of engineers, designers, technologists and testing specialists supports projects from concept development and technical documentation, through calculations and simulations, design, prototyping and manufacturing, to comprehensive testing and implementation into production.
BOSMAL’s extensive technical facilities enable testing of materials and individual components, as well as complex assemblies, devices, systems and complete objects.
Our capabilities include, among others, climatic and environmental testing, vibration and shock testing, durability, material and corrosion testing, EMC/ESD testing, verification of IP protection ratings, as well as testing of batteries, power supply systems and powertrains. We also support the development and validation of unmanned systems – including aerial and maritime platforms – covering their structures, electronics, propulsion systems, power sources and environmental resistance.
BOSMAL’s capabilities for the defence sector are confirmed by:
- OiB Accreditation No. 67/MON/2024,
- AQAP 2110:2016 certification,
- Licence of the Polish Ministry of the Interior and Administration No. B-138/2023.
Our Testing Laboratory also holds PCA Accreditation No. AB 128 in accordance with PN-EN ISO/IEC 17025, covering more than 600 accredited testing methods.
BOSMAL provides a single technology base for the entire process – from concept, design and prototype development to testing, validation and implementation.
The development of modern defence systems requires the integration of design, manufacturing and testing capabilities.
BOSMAL brings all these areas together within a single organisation, supporting manufacturers and suppliers in the defence sector throughout the successive stages of development and validation of new solutions.
For over 50 years, we have been delivering advanced engineering projects for industry. Our interdisciplinary team of engineers, designers, technologists and testing specialists supports projects from concept development and technical documentation, through calculations and simulations, design, prototyping and manufacturing, to comprehensive testing and implementation into production.
BOSMAL’s extensive technical facilities enable testing of materials and individual components, as well as complex assemblies, devices, systems and complete objects.
Our capabilities include, among others, climatic and environmental testing, vibration and shock testing, durability, material and corrosion testing, EMC/ESD testing, verification of IP protection ratings, as well as testing of batteries, power supply systems and powertrains. We also support the development and validation of unmanned systems – including aerial and maritime platforms – covering their structures, electronics, propulsion systems, power sources and environmental resistance.
BOSMAL’s capabilities for the defence sector are confirmed by:
- OiB Accreditation No. 67/MON/2024,
- AQAP 2110:2016 certification,
- Licence of the Polish Ministry of the Interior and Administration No. B-138/2023.
Our Testing Laboratory also holds PCA Accreditation No. AB 128 in accordance with PN-EN ISO/IEC 17025, covering more than 600 accredited testing methods.
BOSMAL provides a single technology base for the entire process – from concept, design and prototype development to testing, validation and implementation.
Products
Testing and Validation of Mobile Shelters and Temporary Shelter Facilities
Testing and Validation of Mobile Shelters and Temporary Shelter Facilities
BOSMAL provides testing, validation and development support for mobile, modular and container shelters as well as temporary shelter facilities.
The scope may include structural safety, airtightness, environmental resistance, material durability, installations and equipment.
Engineering and laboratory capabilities allow structural calculations and simulations to be combined with prototype and complete-module testing, supporting manufacturers from product development through technical validation.
Scope: FEA and engineering calculations; load-bearing capacity, stiffness and deformation analysis; resistance to debris loads, blast wave, shocks and dynamic impacts; air- and watertightness tests and verification of positive/negative pressure retention; climatic, humidity, rain, dust, vibration, shock and fatigue testing; corrosion, UV, thermal cycling, chemical resistance and material analysis.
Largest climatic chamber: 11.5 × 4.7 × 4.2 m, standard operation up to +65°C.
Tow coupling testing according to UN Regulation No. 55 is also available. Reporting is performed in accordance with EN ISO/IEC 17025 where covered by accreditation.
Largest climatic chamber: 11.5 × 4.7 × 4.2 m, standard operation up to +65°C.
Tow coupling testing according to UN Regulation No. 55 is also available. Reporting is performed in accordance with EN ISO/IEC 17025 where covered by accreditation.
Electromagnetic Compatibility (EMC) Testing
Electromagnetic Compatibility (EMC) Testing
BOSMAL provides comprehensive electromagnetic compatibility (EMC) testing of electrical and electronic components for military, industrial and automotive applications.
The new ALSE chamber enables assessment of conducted and radiated emissions as well as immunity to electromagnetic disturbances over a wide frequency range.
The facility can also test large and high-voltage devices, with power supply, cooling and continuous functional monitoring available during testing.
ALSE (Absorber-Lined Shielded Enclosure):
- usable dimensions 7.55 × 6.05 × 3.10 m;
- specimen mass up to 700 kg;
- frequency range 10 kHz–40 GHz;
- programmable DUT supply up to 1500 V DC / 2 × 500 A;
- cooling circuits, compressed air and communication interfaces;
- video monitoring.
Scope: conducted and radiated emissions and immunity testing.
Compliance includes CISPR 25, ISO 11452 and MIL-STD-461G.
Additional RF immunity system: 100 kHz–7.12 GHz, field strength up to 600 V/m, with radar pulse and BCI capability.
- usable dimensions 7.55 × 6.05 × 3.10 m;
- specimen mass up to 700 kg;
- frequency range 10 kHz–40 GHz;
- programmable DUT supply up to 1500 V DC / 2 × 500 A;
- cooling circuits, compressed air and communication interfaces;
- video monitoring.
Scope: conducted and radiated emissions and immunity testing.
Compliance includes CISPR 25, ISO 11452 and MIL-STD-461G.
Additional RF immunity system: 100 kHz–7.12 GHz, field strength up to 600 V/m, with radar pulse and BCI capability.
Material, Corrosion and Ageing Testing
Material, Corrosion and Ageing Testing
BOSMAL provides comprehensive testing of materials, coatings and finished products to support durability assessment, quality verification and failure investigation.
The scope includes:
- material identification,
- mechanical and physicochemical properties,
- microscopy and metallography,
- corrosion and ageing tests,
- resistance to light and environmental exposure.
The laboratory also performs failure analysis to identify the mechanisms and root causes of defects in components operating under demanding conditions.
Corrosion testing in artificial atmospheres: salt spray, immersion, condensation, SO₂ and climatic cycles; standards include ISO 9227, ASTM B117, ASTM G85, VDA 233-102 and ISO 11997-1/-2.
Testing in Cl₂, SO₂, NO₂ and H₂S atmospheres, with concentrations depending on the method up to 2700 ppb.
Material testing includes chemical composition, polymer and material identification, microscopy, metallography, mechanical and physicochemical properties and technical cleanliness.
Ageing tests cover temperature, humidity, ozone, UV, radiation and weather exposure.
Samples, coatings, components and complete products can be tested, including failure analysis.
Testing in Cl₂, SO₂, NO₂ and H₂S atmospheres, with concentrations depending on the method up to 2700 ppb.
Material testing includes chemical composition, polymer and material identification, microscopy, metallography, mechanical and physicochemical properties and technical cleanliness.
Ageing tests cover temperature, humidity, ozone, UV, radiation and weather exposure.
Samples, coatings, components and complete products can be tested, including failure analysis.
IP Protection Testing – Dust and Water Resistance
IP Protection Testing – Dust and Water Resistance
BOSMAL performs accredited IP protection testing for devices, components and assemblies exposed to dust, solid objects and water.
The scope covers the full IP classification, from protection against access to hazardous parts and ingress of solid objects to rain, water jets, immersion and high-pressure washing.
Tests can be carried out according to international standards, manufacturer requirements or a customised test programme agreed with the customer.
IP testing scope:
- IP1X–IP4X (protection against access to hazardous parts and solid objects), additional letters A–C;
- IP5X and IP6X according to EN 60529,
- IP5KX and IP6KX according to ISO 20653.
Water resistance:
- IPX1, IPX2 (dripping water), IPX3, IPX4, IPX4K (rain/spray), IPX5, IPX6, IPX6K (water jets), IPX7 and IPX8 (immersion), IPX9 and IPX9K (high-pressure washing).
Dust chambers: 1 m³ and 0.3 m³; 1 m³ chamber: 1000 × 1000 × 1000 mm, up to 100°C, optional negative pressure.
Immersion tank: Ø900 mm lifting platform, 1.5 m water column, adjustable water temperature, immersion depth and test duration.
High-pressure system: 30–120 bar, water temperature <80°C.
Standards: EN 60529/A2, ISO 20653, JIS D 0203, DIN 40050-9 and manufacturer specifications.
All BOSMAL IP tests are accredited under PCA AB 128.
Complementary water resistance tests are also available, including the Wading Test and High Pressure Cleaning with Thermal Shock.
- IP1X–IP4X (protection against access to hazardous parts and solid objects), additional letters A–C;
- IP5X and IP6X according to EN 60529,
- IP5KX and IP6KX according to ISO 20653.
Water resistance:
- IPX1, IPX2 (dripping water), IPX3, IPX4, IPX4K (rain/spray), IPX5, IPX6, IPX6K (water jets), IPX7 and IPX8 (immersion), IPX9 and IPX9K (high-pressure washing).
Dust chambers: 1 m³ and 0.3 m³; 1 m³ chamber: 1000 × 1000 × 1000 mm, up to 100°C, optional negative pressure.
Immersion tank: Ø900 mm lifting platform, 1.5 m water column, adjustable water temperature, immersion depth and test duration.
High-pressure system: 30–120 bar, water temperature <80°C.
Standards: EN 60529/A2, ISO 20653, JIS D 0203, DIN 40050-9 and manufacturer specifications.
All BOSMAL IP tests are accredited under PCA AB 128.
Complementary water resistance tests are also available, including the Wading Test and High Pressure Cleaning with Thermal Shock.
Testing of Unmanned Systems – Aerial, Ground and Marine
Testing of Unmanned Systems – Aerial, Ground and Marine
BOSMAL provides comprehensive testing, validation and development support for unmanned systems intended for defence and special applications.
The scope covers unmanned aerial, ground and marine platforms as well as their components and subsystems.
Within a single R&D centre, we can verify structures, materials, electronics, power supply and propulsion systems, and resistance to environmental conditions.
The offer is complemented by metrology, structural analyses, prototyping and the development of customised test programmes.
Testing may include:
- EMC/ESD of electronics, electrical insulation, harnesses and connectors, and electrical parameters;
- battery-pack testing, charging/discharging, vibration and mechanical shock;
- electric propulsion testing;
- assessment of composites and structures, fatigue durability, material identification, microscopy and metallography;
- IP dust and water protection, thermal shock, extreme-temperature climate, humidity, rain, corrosion and ageing.
For marine systems, salt-environment and salt-fog exposure, corrosion and erosion, and pressure testing are also available. BOSMAL also provides metrology, prototype trials, structural analysis and customised test programmes.
Defence-sector capabilities are confirmed by Defence & Security Accreditation No. 67/MON/2024, AQAP 2110:2016 and Polish Ministry of the Interior and Administration Licence No. B-138/2023.
- EMC/ESD of electronics, electrical insulation, harnesses and connectors, and electrical parameters;
- battery-pack testing, charging/discharging, vibration and mechanical shock;
- electric propulsion testing;
- assessment of composites and structures, fatigue durability, material identification, microscopy and metallography;
- IP dust and water protection, thermal shock, extreme-temperature climate, humidity, rain, corrosion and ageing.
For marine systems, salt-environment and salt-fog exposure, corrosion and erosion, and pressure testing are also available. BOSMAL also provides metrology, prototype trials, structural analysis and customised test programmes.
Defence-sector capabilities are confirmed by Defence & Security Accreditation No. 67/MON/2024, AQAP 2110:2016 and Polish Ministry of the Interior and Administration Licence No. B-138/2023.
Vibration and Mechanical Shock Testing
Vibration and Mechanical Shock Testing
BOSMAL performs resistance testing of components, assemblies and devices under sinusoidal and random vibration and mechanical shock.
Tests can reproduce real operating loads using recorded time histories.
Vibration systems can operate with climatic chambers, enabling mechanical loads to be combined with temperature and humidity exposure.
BOSMAL also provides design and manufacture of dedicated test fixtures and development of customised test programmes.
Vibration systems: 36, 80 and 125 kN.
125 kN system:
- force 125 kN (sine/random), 360 kN (mechanical shock);
- frequency range 4–2000 Hz;
- max. displacement 100 mm;
- max. acceleration 100 g (sine/random) and 200 g (shock); max. payload 2000 kg;
- vertical table 1200 × 1200 mm;
- horizontal table 1500 × 1500 mm.
Integrated climatic chamber:
- dimensions: 2800 × 2500 × 1400 mm;
- temperature −45…+180°C;
- humidity 10–98% RH.
Testing includes IEC/EN 60068-2-6, IEC/EN 60068-2-64, IEC/EN 60068-2-27 and other standards or customer specifications.
125 kN system:
- force 125 kN (sine/random), 360 kN (mechanical shock);
- frequency range 4–2000 Hz;
- max. displacement 100 mm;
- max. acceleration 100 g (sine/random) and 200 g (shock); max. payload 2000 kg;
- vertical table 1200 × 1200 mm;
- horizontal table 1500 × 1500 mm.
Integrated climatic chamber:
- dimensions: 2800 × 2500 × 1400 mm;
- temperature −45…+180°C;
- humidity 10–98% RH.
Testing includes IEC/EN 60068-2-6, IEC/EN 60068-2-64, IEC/EN 60068-2-27 and other standards or customer specifications.
Dynamic testing of mechanical shock and inertial loads on components and subassemblies
Dynamic testing of mechanical shock and inertial loads on components and subassemblies
BOSMAL provides dynamic mechanical shock and inertial load testing with precise reproduction of specified acceleration and deceleration time histories.
The test bench is intended, among others, for verification of the safety and integrity of rechargeable energy storage systems (REESS) and other components and assemblies exposed to severe dynamic loads.
Testing can be performed according to applicable standards as well as customised load profiles agreed with the customer.
The bench enables UNECE Regulation No. 100, Test 9C “Mechanical Shock”, and ISO 6469-1:2019, §6.4.1.1.2 “Inertial load at a vehicle crash”.
Parameters:
hydraulic actuator
- 400 kN force,
- 800 mm stroke;
- maximum speed 9.5 m/s;
- maximum specimen mass 600 kg including fixtures and instrumentation;
test table 2450 × 1450 mm.
Closed-loop control enables generation and iterative matching of specified acceleration/deceleration pulses.
Supported control-signal formats: dat, rsp, rpc, acq, tgt, mat, txt, csv. The bench can also perform other tests requiring precise reproduction of acceleration or deceleration time histories.
Parameters:
hydraulic actuator
- 400 kN force,
- 800 mm stroke;
- maximum speed 9.5 m/s;
- maximum specimen mass 600 kg including fixtures and instrumentation;
test table 2450 × 1450 mm.
Closed-loop control enables generation and iterative matching of specified acceleration/deceleration pulses.
Supported control-signal formats: dat, rsp, rpc, acq, tgt, mat, txt, csv. The bench can also perform other tests requiring precise reproduction of acceleration or deceleration time histories.
Engineering Design, Prototyping and Manufacturing
Engineering Design, Prototyping and Manufacturing
BOSMAL provides comprehensive design and manufacturing support – from concept and design assumptions through 3D modelling, engineering calculations and documentation to prototype manufacture, measurement, testing and implementation.
The offer also includes special-purpose machines, test and measurement equipment and dedicated tooling.
Combining an engineering office, manufacturing facilities, metrology and laboratories enables projects to be delivered from initial concept to a completed and validated product.
CAD/CAE/CAM design, 3D models and 2D documentation; FEA including linear, nonlinear, dynamic, modal and coupled-field analyses.
Software includes CATIA V5, ANSYS 2024 R1, Siemens NX, Autodesk Inventor, AutoCAD, Abaqus, Solid Edge and Creo.
CAM programming and 2.5/3/5-axis CNC machining.
Manufacturing capabilities include 3- and 5-axis CNC milling, conventional milling, turning, grinding, wire EDM and welding.
Production of models, mock-ups, prototypes, test and measurement fixtures, technological tooling and special-purpose machines.
Dimensional inspection with metrology reports, followed by verification and testing of the finished product.
Software includes CATIA V5, ANSYS 2024 R1, Siemens NX, Autodesk Inventor, AutoCAD, Abaqus, Solid Edge and Creo.
CAM programming and 2.5/3/5-axis CNC machining.
Manufacturing capabilities include 3- and 5-axis CNC milling, conventional milling, turning, grinding, wire EDM and welding.
Production of models, mock-ups, prototypes, test and measurement fixtures, technological tooling and special-purpose machines.
Dimensional inspection with metrology reports, followed by verification and testing of the finished product.
Large-Scale Climatic and Environmental Testing
Large-Scale Climatic and Environmental Testing
BOSMAL tests vehicles, machines, equipment and components under controlled high- and low-temperature and humidity conditions.
Large-scale climatic chambers enable testing of complete vehicles and other large objects, including special-purpose equipment.
Tests assess functionality, cold starting, durability and product behaviour under extreme environmental conditions. Individual temperature profiles and customised test programmes can be developed to meet customer requirements.
Two large-scale, free-standing climatic chambers, each 11.5 × 4.7 × 4.2 m.
Chamber 1: temperature −65…+65°C; humidity up to 98% RH at 55°C.
Chamber 2: temperature 0…+65°C; humidity up to 98% RH at 55°C.
Gate size: 4.7 × 4.2 m.
Additionally, three 11.5 m long chambers are available for conditioning and testing objects, particularly vehicles: temperature −35…+65°C; humidity up to 98% RH at 55°C; internal space 11.5 × 2.28 × 2.55 m.
Functional and durability testing, as well as evaluation of starting and operation under extreme temperatures, can be performed.
Chamber 1: temperature −65…+65°C; humidity up to 98% RH at 55°C.
Chamber 2: temperature 0…+65°C; humidity up to 98% RH at 55°C.
Gate size: 4.7 × 4.2 m.
Additionally, three 11.5 m long chambers are available for conditioning and testing objects, particularly vehicles: temperature −35…+65°C; humidity up to 98% RH at 55°C; internal space 11.5 × 2.28 × 2.55 m.
Functional and durability testing, as well as evaluation of starting and operation under extreme temperatures, can be performed.
