Abstract: Methods and systems for data smoothing raw data such as stress data. The present invention may utilize various techniques to smooth data such as dropping data using a stress threshold, dropping data by resample (or decimation), and smoothing by dynamic binning. Additionally, the present invention may utilize a transform function to estimate stress from a stress sensor to areas of peak stress. In an exemplary application, the present invention can be utilized to reduce stress data collected by a plurality of embedded stress sensors in a rocket motor for purposes of computing service life of the motor.