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In-Line Test Systems, XILS and MILS | Productronica 2025 – Product Highlight

By 01.10.2025October 3rd, 2025Knowledge Hub

XILS and MILS Smart In-Line PCB Testing

The Challenge

Reliability & Precision vs. Time & Space Efficiency

In today’s electronics industry, the real challenge lies in finding the balance between ensuring maximum reliability and accuracy in testing processes and, at the same time, optimizing time and space resources within the production plant. PCBs are becoming increasingly complex, with higher component density, advanced connectivity, and strict quality requirements. On top of this comes the need to adapt to shorter product life cycles and highly variable production volumes.

In this scenario, engineers need testing solutions that ensure robust, repeatable, and traceable tests, without compromising productivity or space efficiency.

XILS Test Systems for Productronica 2025

The Technology

Mechanical Precision and Smart Control

The advanced in-line handlers are designed as a cost-effective, compact, and easy-to-integrate solution for production environments. They are widely used in ICT (In-Circuit Test), ISP (In-System Programming), and FCT (Functional Test) applications.

Their architecture often relies on a dual transport system, enabling the connection of multiple units in series and helping manufacturers optimize floor space. This setup allows for a continuous and synchronized flow of PCBs, contributing to an efficient and bottleneck-free testing process.

Test de PCB de EIIT para Productrónica 2025

In addition, modern handlers increasingly rely on software-based configuration to support quick adaptation to different products and test requirements, minimizing downtime and setup effort. Many systems also incorporate mechanisms that ensure precise connector handling, contributing to reliable and repeatable results.

Finally, handlers are built to provide maximum flexibility in the integration of test technologies, supporting instrumentation from various industry-leading manufacturers and accommodating methodologies such as Digital ICT, boundary scan, LED testing, or ASA (Analog Signature Analysis).

The result is a technology that combines mechanical precision, smart control, and compatibility, providing manufacturers with a robust and scalable platform that adapts to the evolving needs of the electronics industry.

The Benefits in Practice

Building on this innovative design, the in-line handlers deliver tangible practical benefits such as:

Higher Throughput

Continuous PCB processing, and steady flow.

Reduced Footprint

Dual conveyor, maximum capacity in minimal space.

Total Flexibility

Software-configurable for different types of tests.

Reduced Downtime

Quick fixture changes and modularity.

Industry Applications

The incorporation of advanced in-line handlers represents a clear competitive advantage for any electronic production plant. Firstly, they allow for significantly reduced cycle times, resulting in higher productivity without compromising test quality. Additionally, their compact and modular design offers the possibility to optimize available factory space, which is especially relevant in environments where every square meter counts.

Moreover, compatibility with standard industry instrumentation and the ability to combine different testing technologies on a single line facilitate the integration of complex processes in a simple and scalable way. This not only ensures more efficient production but also provides the flexibility needed to adapt to new products and requirements without the need for significant additional investments.

Finally, ergonomics in fixture replacement and integrated communication between handlers reduce operational costs and simplify the daily tasks of engineering teams. In this way, companies not only improve the reliability and traceability of their tests, but also achieve a perfect balance between performance, precision, and efficiency.

Cambio de Fixture en Sistema de Test en Línea XILS

The Solution

eXtended & Middle In-Line Systems: XILS & MILS

The XILS600, XILS800, and MILS700 handler series has been designed with a single principle in mind: to provide smart and scalable solutions for PCB testing in high-demand environments. Their serial connectivity allows the creation of fully integrated production lines, where each handler operates in sync with the others, ensuring a continuous test flow without interruptions.

This modularity, combined with compatibility with multiple test technologies, makes XILS and MILS a benchmark solution for companies seeking a system ready for today and scalable for the future.

What Makes Controlar’s Handlers Stand Out:

  • Optimized dual SMEMA-level transport system that eliminates the need for parallel lines, ensuring exceptional space efficiency.

  • Software-driven configuration that allows fast reconfiguration for different test requirements without complex physical modifications.

  • Side actuation for USB and Ethernet connectors, ensuring precise insertion, reduced wear, and higher test reliability.

  • Seamless integration with instrumentation and solutions from leading manufacturers (Teradyne, Keysight, Checksum, TRI, Goepel electronic, National Instruments, SMH, etc.).

The XILS600 is optimized for ISP (flashing) and FCT (functional) testing, featuring a dual SMEMA transport system that eliminates parallel lines and an instrumentation subrack that reduces cabling distance to the DUT, increasing reliability. Its main advantages include compactness and multipurpose use, serial connection with other XILS units, flexible software-based configuration, side actuation for USB and Ethernet connectors, ergonomic fixture replacement, support for LED testing, and a handling time of approximately 6 seconds.

XILS800 Handler en Línea EIIT

The XILS800 is ideal for ICT with high test point density or large-sized PCBs, featuring a robust iron and aluminum structure capable of withstanding forces up to 15 kN, delivering reliability, speed, and scalability in demanding environments. Its main advantages include compatibility with ICT, ISP, and FCT, modular and flexible design, serial connection with other handlers, software-based configuration, precise side actuation for DUT connectors, support for leading manufacturers such as Teradyne, Keysight, Checksum, and TRI, parallel testing capability to reduce cycle times, and a handling time of approximately 7 seconds.

MILS700 Handler en Línea de EIIT

The MILS700 combines compactness, speed, and cost-effectiveness, making it ideal for ISP and FCT environments where quick fixture changes and cost optimization are crucial. Its design allows integration of instrumentation from various manufacturers and serial connection with other handlers to form complete lines. Key advantages include compactness and multipurpose use, compatibility with Teradyne, Keysight, Checksum, TRI, and more, fast and ergonomic fixture changes, reduced footprint, precise side actuation for USB/Ethernet connectors, and a handling time of approximately 5 seconds.

Discover our Solutions at Productronica

Visitors to Productronica 2025 will be able to see the XILS600, XILS800, and MILS700 in action at the EIIT and Controlar booth, experiencing firsthand how these in-line test systems represent smart, scalable, and reliable solutions for PCB testing in high-demand environments.

PCB Testing de EIIT para Productronica 2025
XILS MILS ICT, ISP & FCT EoL TEST SYSTEMS COMPACT AUTOMATIC MODULAR SPACE EFFICIENCY ELECTRONICS PRODUCTRONICA 2025
XILS MILS ICT, ISP & FCT EoL TEST SYSTEMS COMPACT AUTOMATIC MODULAR SPACE EFFICIENCY ELECTRONICS PRODUCTRONICA 2025
XILS MILS ICT, ISP & FCT EoL TEST SYSTEMS COMPACT AUTOMATIC MODULAR SPACE EFFICIENCY ELECTRONICS PRODUCTRONICA 2025