Failure analyses
Failure analysis / component tests and evaluation

Optimising a product/ process often is associated with a detailed material analysis of the raw material that is used for a plastic product and of the end product properties. In many cases, it can be detected that already small variations of the raw material properties (“batch variations”) can have diverse implications on the process and the component properties. This becomes exceptionally clear facing the current process variants of injection moulding, such as gas and water assisted injection moulding or sandwich injection moulding as well as looking at hybrid component structures like two-component injection moulding hard-soft-composites or metal-plastic-composites.

Examples of typical phenomena are:

  • gas breakthroughs at the melt front,
  • uneven distribution of the core component at sandwich injection moulding,
  • reduced adhesion composite at two-component injection moulding components,
  • raised stresses in the component,
  • low weld line strength,
  • declined mechanical properties of the component,
  • insufficient surface properties,
  • variations of the process capability,
  • partial fillings of individual cavities at multi-cavity mould,
  • etc.

In addition, the following finishing steps, such as varnishing and joining, are strongly influenced by the raw material properties – especially if the properties of the used raw materials are not necessarily constant during the production.

Difficulties for the plastic processor consist in:
  a) applying adequate test methods for his components in order to check the quality,
  b) carrying out an adequate raw material test in order to guarantee the quality of the used raw materials,
  c) in the case of failure, applying those test methods which offer a safe conclusion on the underlying problem.

Beyond that, the room for interpretation at plastic test methods is not insignificant. As a consequence, the right conclusions can only be drawn from a raw material or component test, if you dispose of the relevant experience.

We offer you support in choosing and interpreting the test methods as well as in transferring the analyses to the task at hand in your company. In doing so, we work closely together with several test laboratories offering a wide range of test methods that are state-of-the-art, and each disposing the biggest know-how in their special field.


Overview of test methods for plastics as PDF (1492 KB)


More information on failure analysis: Technical information failure analysis