Mechatronic products usually endure the variable stress spectrum when they operate in certain operational condition and environmental condition, which obey the Weibull distribution. In accordance with the features of mechatronic product, this paper analyzes the failure mode, its corresponding sensitive stress and the design principles of life testing profiles. Based on the above analyses, this paper presents a synthetic stress life testing method based on the hybrid Weibull distribution and its statistical method under variable stress spectrum to evaluate the reliability and life indices of mechatronic products. Because the mechatronic products have many characteristics such as high price, long life and small testing samples, the synthetic stress life testing method under variable load spectrum can simulate the real various spectra, decrease the life testing time and reduce the testing samples. So it is effective to carry out the life testing to mechatronic products. The application results of hydraulic pumps indicate that this method can easily handle the experimental data under variable amplitude spectrum, obtain the high precision parameters point estimation and confidence interval estimation and reduce the testing cost greatly.