Introduction
In today’s competitive manufacturing and R&D environments, polymer failure analysis plays a key role in assuring product quality, reliability, and longevity. At ResolveMass Laboratories Inc., we specialize in advanced polymer testing methodologies that empower scientists, engineers, and manufacturers to pinpoint the root cause of polymer degradation, structural weakness, or processing issues. This blog explores how a real-life failure was diagnosed and resolved using cutting-edge techniques, illustrating the vital role of polymer failure analysis.
Understanding Polymer Failure Analysis
Polymer failure analysis involves a thorough investigation into why a polymer-based material did not perform as expected. Failures may manifest as cracking, discoloration, delamination, brittleness, or complete disintegration. The causes can range from:
- Material selection errors
- Processing anomalies
- Environmental stressors (UV, humidity, temperature)
- Chemical incompatibility
Using a battery of analytical tools and scientific methods, experts can trace failure back to its origin, helping prevent future incidents and guide material improvements.
Why Choose ResolveMass Laboratories for Polymer Failure Analysis?
With over a decade of specialized experience in materials science, ResolveMass Laboratories Inc. has emerged as a leading name in the field of polymer failure analysis. Our clients trust us because of our:
- State-of-the-art instrumentation
- Certified laboratory environment
- Data-driven reporting
- Proven expertise across multiple industries
We offer comprehensive testing services such as:
- Custom Polymer Synthesis
- Gel Permeation Chromatography (GPC) Analysis
- Glass Transition Temperature (Tg) Testing
- NMR for Peptide and Polymer Structure Analysis
The Process of Polymer Failure Analysis
Polymer failure analysis is a step-by-step process. At ResolveMass, it typically involves:
1. Visual and Microscopic Examination
The initial step is a thorough physical and visual inspection to identify surface defects and cracking patterns. High-resolution microscopy aids in observing morphological changes.
2. Thermal Analysis
We use Glass Transition Temperature (Tg) Testing to determine whether thermal history contributed to the failure. Changes in Tg may indicate chemical degradation or plasticizer migration.
3. Molecular Weight Analysis
Using GPC Analysis, we determine molecular weight distributions. A drop in molecular weight often signals polymer chain scission due to hydrolysis, oxidation, or UV exposure.
4. Spectroscopic Techniques
Spectroscopy, particularly NMR, helps identify compositional changes, contamination, or unexpected crosslinking.
5. Custom Synthesis and Control Testing
When necessary, we reproduce the polymer using custom polymer synthesis to compare against the failed sample.
Each step contributes to building a forensic-level understanding of the polymer failure analysis case.
Case Study: Medical Device Catheter Failure
Background
A leading medical device manufacturer approached ResolveMass Laboratories with a recurring failure in their thermoplastic polyurethane (TPU) catheters. Cracks were developing under storage conditions, well before the expiration date.
Investigative Testing Summary
- Visual Inspection: Identified microcracks along the catheter length.
- Tg Testing: Tg had dropped by 15°C, suggesting plasticizer migration.
- GPC Analysis: Indicated a 22% decrease in number-average molecular weight (Mn).
- NMR Analysis: Showed evidence of hydrolysis and residual solvent contamination.
Root Cause
It was found that residual DMAC solvent used during extrusion was not adequately removed. This led to hydrolytic degradation over time, lowering molecular weight and Tg.
Resolution
The client altered the drying protocol and changed the solvent system, leading to a 98% reduction in failure rate in the next 6-month production batch.
This case illustrates how advanced polymer failure analysis can lead to actionable results, helping clients ensure safety and regulatory compliance.
Explore our GPC services, NMR techniques, and glass transition testing to get a comprehensive overview of how we empower material scientists and product developers.
Conclusion
When precision, safety, and product reliability matter most, polymer failure analysis from ResolveMass Laboratories Inc. becomes an essential service. Our evidence-backed, science-driven approach ensures every material fault is thoroughly investigated and resolved. From root-cause identification to actionable insights, we provide unmatched analytical clarity.
Tap into our custom synthesis solutions and cutting-edge testing methods to elevate your R&D and QA capabilities.
If you’re dealing with unexpected polymer degradation, our experts are here to help.
Contact us today | Get a Consultation | Schedule Your Test
Top 10 Frequently Asked Questions on Polymer Failure Analysis
1. What is polymer failure analysis?
Polymer failure analysis is a structured investigation used to determine the cause of failure in polymer-based materials. It combines visual inspection, spectroscopy, thermal testing, and chemical analysis to identify root causes such as stress, environmental exposure, or processing errors.
2. How is Tg (Glass Transition Temperature) relevant in failure analysis?
Tg represents the temperature at which a polymer transitions from rigid to flexible. A shift in Tg can indicate chemical degradation, presence of residual solvents, or plasticizer loss, all of which may contribute to failure.
3. What industries require polymer failure analysis?
Industries such as medical devices, aerospace, automotive, electronics, packaging, and construction regularly use polymer failure analysis to ensure compliance, safety, and performance.
4. What are the signs of polymer degradation?
Common signs include discoloration, cracking, tackiness, brittleness, and loss of strength or flexibility. These signs often warrant detailed failure analysis.
5. What techniques are used in polymer failure analysis?
Techniques include Gel Permeation Chromatography (GPC), Nuclear Magnetic Resonance (NMR), Scanning Electron Microscopy (SEM), Differential Scanning Calorimetry (DSC), and Infrared Spectroscopy (FTIR).
6. Can ResolveMass analyze both thermoplastics and thermosets?
Yes, our lab is equipped to handle failure analysis in both thermoplastics and thermosets, using customized protocols and material-specific techniques.
7. How long does a polymer failure analysis take?
Typically, the full cycle takes 5–7 business days depending on complexity. Emergency analysis options are available for critical failures.
8. What kind of reporting can I expect?
We provide detailed reports including method summaries, test data, root cause interpretations, and recommendations. Photographic evidence and spectra are included.
9. Does ResolveMass offer comparative testing against reference materials?
Yes. We can synthesize reference materials using our custom polymer synthesis unit for accurate comparison.
10. How do I initiate a testing project?
You can initiate your project by contacting us directly through our contact page. One of our material scientists will guide you through the requirements and next steps.
Need expert help with a material failure? Contact us now to begin your polymer analysis journey.
ResolveMass Laboratories Inc.: Experience, Expertise, and Trust You Can Count On
ResolveMass Laboratories Inc. is a leading name in nitrosamine testing across the United States and Canada. With over a decade of experience, our PhD-level scientists specialize in Mass Spectrometry and nitrosamine impurity chemistry. We offer complete in-house solutions, including risk assessment, confirmatory analysis, regulatory documentation, and expert consultation. As one of the few Canadian CROs, we also provide custom synthesis of rare nitrosamine impurities unavailable elsewhere. Our commitment to advanced technology and regulatory compliance ensures accurate results and trusted partnerships. Choose ResolveMass Laboratories for precise and transparent nitrosamine testing services.
Ready to Get Started?
📩 Contact our expert team
📞 Request a quote for method development
📅 Book a consultation with our scientists
🧪 Submit your sample for testing
References
- Joanna Drzeżdżon, Dagmara Jacewicz, Alicja Sielicka, Lech Chmurzyński, “A review of new approaches to analytical methods to determine the structure and morphology of polymers,” TrAC Trends in Analytical Chemistry, Volume 118, 2019, Pages 470-476, ISSN 0165-9936, https://doi.org/10.1016/j.trac.2019.06.013.
- Hayes, M. D., Edwards, D. B., & Shah, A. R. (2015). Long-term failure mechanisms in plastics. In M. D. Hayes, D. B. Edwards, & A. R. Shah (Eds.), Fractography in failure analysis of polymers (pp. 93–110). William Andrew Publishing. https://doi.org/10.1016/B978-0-323-24272-1.00005-2
