In 2024, a peer-reviewed study introduced improvements to the replica tape test method including an increased range for Coarse, X-Coarse, and X-Coarse Plus replica tapes and a new conversion technique. The resultant conversion table can be used with analog micrometers and provides a simpler alternative to the legacy ‘averaging’ technique. The conversion table is not required for the Testex Digital Micrometer as it makes the calculations automatically.

Previously, if readings made with either the legacy Coarse or X-Coarse replica tape fell within the 'overlap range' of 38 to 64 µm (1.5 to 2.5 mils), a second reading was be taken in the same spot with the other grade of tape. If BOTH readings were within the above 'overlap range’, the average of the two readings were recorded as the ‘Profile Measurement’. If only one reading was outside of the Overlap Range, it was recorded as the first reading and a second reading was taken with the same grade of replica tape. Averaging those two readings together yielded a 'Profile Measurement'. The legacy averaging technique is still valid and supported by international standards.

The High Accuracy Burnishing Tool includes a spring-loaded burnishing ball which is depressed into the base of the tool exerting the perfect amount of pressure to burnish (create) a replica. It reduces operator influence, providing an extended range and ±8 µm (0.3 mil) accuracy for Testex Replica Tape.

For concave surfaces, the narrower curved top of the tool can be used to create replicas.

The Classic Stick-type Burnishing Tool remains a valid measurement practice and is recognized by international standards. Care should be given to avoid applying too much force. Excessive force can lead to inaccurate measurements

All versions of Coarse and X-Coarse replica tape use the same trusted replica foam, incompressible backing, and HT (high temperature) formulation that have been sold for decades. There is no functional difference between the legacy rolls of Coarse and X-Coarse replica tape, and the new strips of Coarse and X-Coarse replica tape that are packaged in cartons.  

The new 'strips' of Coarse and X-Coarse replica tape simply feature a modernized design and packaging.

Strips of X-Coarse Plus replica tape feature thicker foam to allow an increased measurement range of 100-150 µm (4.0-6.0 mils). Strips and rolls of X-Coarse Plus replica tape should not be used interchangeably.

Improvements include:

• Easy-Open, Easy-Close Carton
• Improved 'Strip' format with Easy-Remove 'Peel-Here' Tab
• Increased X-Coarse Plus Range—100-150 µm (4.0-6.0 mils).

Returning Features

• Same trusted Coarse and X-Coarse replica foam
• Same High Temperature (HT) Formulation for better performance on hot surfaces
• 50 strips (impressions) per carton/roll