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Since retiring, he continues to be active in consulting and writing. A revised and expanded version of his well-known 1996 book, Plastics Failure Guide: Cause and Prevention, is in preparation. He

How to fill out plastics failure analysis

1. To fill out a plastics failure analysis, start by gathering all relevant information about the failure, such as the material used, the manufacturing process, the design specifications, and any known external factors that may have contributed to the failure.
2. Next, visually inspect the failed part or sample to identify any visible signs of failure, such as cracks, fractures, deformations, or discoloration. Document these findings with clear photographs or drawings.
3. Conduct non-destructive testing methods, such as ultrasonic testing or X-ray imaging, to identify any internal defects or anomalies that may have led to the failure. This can provide valuable insights into the root cause of the failure.
4. Perform mechanical testing on both the failed part and comparison samples to evaluate the material's mechanical properties, such as tensile strength, flexural strength, or impact resistance. This will help in determining if the material met the required specifications or if there were any manufacturing defects.
5. Analyze the collected data and observations to identify the primary reason for the failure. This could be due to material properties, design flaws, manufacturing defects, improper usage or handling, or a combination of factors.
6. Provide a detailed report summarizing the failure analysis, including a clear description of the failure mode, the identified root cause, and any recommendations for preventing future failures. This report should be understandable to both technical and non-technical stakeholders.

As for who needs plastics failure analysis, it is essential for industries that use plastics in their products. This includes manufacturers, engineers, quality control personnel, and anyone involved in the design, production, or use of plastic components. Understanding the causes of failure helps in improving product quality, identifying potential risks, and implementing corrective measures to prevent future failures.

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