Plastic and Rubber Failure Analysis Services

Polymer materials are vulnerable to degradation and cracking when exposed to chemical agents and environmental stressors. Key failure mechanisms include environmental stress cracking (ESC), solvation and plasticisation, and chemical attack, each capable of compromising structural integrity. Specific interactions with common household or industrial substances—such as cleaning agents, oils, or solvents—can rapidly induce crazing, brittle fracture, and premature product failure, especially under mechanical load or elevated temperatures.

Polymers are sensitive to heat, ultraviolet (UV) light, and other forms of radiation. Without adequate stabilisation, they are prone to rapid structural degradation, which can manifest as surface discoloration, embrittlement, cracking, and ultimately, mechanical failure. These effects are particularly pronounced under prolonged exposure to elevated temperatures, intense UV radiation, ozone or oxidative environments, where the polymer’s molecular structure becomes compromised.

Using an incorrect material for an application is a common cause of polymer failure. A lack of understanding of polymer interactions with chemicals, environments, and long-term responses often leads to premature failure.

Plastic and rubber products are sensitive to long-term mechanical loads. These loads can be static - resulting in creep of the material - or dynamic loads inducing fatigue mechanisms. Over time, Creep and fatigue cause the strength and stiffness of plastic components to be significantly lower than the nominal values quoted on standard data sheets. A lack of understanding or consideration of the significance of long-term mechanical effects is a common and preventable cause of premature failure in polymer-based systems.

Many polymers are inherently notch-sensitive materials, meaning that surface notches, defects, or stress concentrators can significantly reduce their mechanical strength and trigger brittle failure, even under moderate loading conditions. While poor component design may introduce geometric notches—such as sharp corners, grooves, or abrupt transitions—internal features like voids, inclusions, weld lines, and microstructural irregularities can also behave as notch-like defects.

Product design is fundamental to ensuring plastic component long term durability. Incorrect design exposes polymeric material weaknesses to long-term loads, chemical environments, high-speed impacts, and fatigue—resulting in brittle failure within a short service life.