This project focuses on developing a simple and cost-effective impact testing rig using basic sensors and electronics to evaluate materials under low-energy impacts. Commercial testing machines like Charpy and Izod are commonly used, but they are often expensive (₹5–10 lakh commercial systems) and not easily accessible for small institutions or student-level research. This setup aims to offer a basic alternative using a drop-weight method and sensor-based data collection

The test rig includes a drop hammer that strikes the specimen from a fixed height (approximately 10 cm or less). Three sensors are used: a 40 kg load cell (with HX711 module) for measuring impact force, an HC-SR04 ultrasonic sensor to track deformation (primarily lateral), and an MPU6050 accelerometer to measure the hammer's acceleration during impact. All sensors are connected to an Arduino Uno, which processes the data using basic calculations related to force, energy, and deformation.

Initial testing was done using an aluminum specimen. One recorded trial showed an impact force of 34.67 N, energy of 0.17 J, lateral deformation of 0.02 mm, and acceleration of 0.08 m/s². More tests are planned to improve consistency and calibration. The frame is built using mild steel and wood, making the setup low-cost and easy to fabricate. The readings were displayed through the Arduino serial monitor.

This project can be further improved with better sensors, heavier drop weights, SD card logging, or automatic hammer release. For now, it works as a small-scale learning and testing tool for light materials like aluminum or plastic. The idea is to make impact testing more affordable and practical for student projects or small labs that cannot access full-scale testing equipment.

Overall, the project demonstrates a practical application of basic mechanical and electronics knowledge to solve a real problem. It also helps in understanding the fundamentals of material behavior under impact loads through hands-on experimentation. This prototype itself was build at a cost of approximately ₹3000 , if made scalable the cost will still be less than that of todays expensive industrial setup available.

In industrial setups, machines that perform instrumented impact testing often cost several lakhs and use closed systems, making them less suitable for small institutions. This rig, while limited in capacity, provides similar conceptual understanding and basic data output at a much lower cost.

The system is also useful in early-stage testing where destructive testing can’t be done at full scale. For example, in defense research environments, low-energy testing can be a useful step before live ballistic trials. With better calibration and force range upgrades, this setup can evolve into a meaningful part of the testing chain for research on composites, light armor materials, or structures subjected to repeated impact.

While this is a student-level project, the design is modular and can be further expanded by research groups or labs looking for scalable solutions. This version supports hands-on learning while emphasizing cost-effectiveness and simplicity, making it easier for students and small labs to perform material testing.