This is far beyond my knowledge base, but you may find this discussion helpful. They talk about using the hdparm and --make-bad-sector options. Buyer beware ....
Another interesting discussion - this one , which talks about the difference between the actual presence of a bad sector and manual creation - depending on which tools you are testing, can these two be registered and / or treated differently?
In any case, the most relevant things I found online were on the forums in hddguru , so maybe people can have a good contribution for you :)
Hope something helps ...