A method of testing a shape memory alloy (SMA) actuated device includes cyclically operating the device. The method further includes determining a number of cycles in a functional life of the device based on observations of the device during the cyclical operation. The functional life is a range of consecutive cycles of operation of the device beginning with a first cycle during which the device performs within a specified limit. The functional life is immediately followed by a cycle during which the device performs outside of the specified limit. The method still further includes applying a progressive substitution sub-process to identify an opportunity to increase the number of cycles in the functional life of the device.