Forensic Engineering
Forensic engineering is a specialized technical service that at INFINITIA is applied to rigorously investigate the origin of failures in materials, components and industrial systems, enabling a precise understanding of the causes that have led to an incident in production, in the product, or following a market claim.
In our materials forensic engineering laboratory, we combine advanced characterization techniques, experimental testing and failure analysis and root cause methodologies to study everything from composition and microstructure to real operating conditions. This approach allows the analysis of variables related to design, manufacturing processes, assembly or final use, generating objective technical evidence based on tests and verifiable data.
The objective is to provide a solid technical diagnosis that enables companies to correct deviations, establish responsibilities when necessary, and define effective actions to prevent recurrence. This service is particularly relevant in industrial environments where product quality, safety and reliability cannot tolerate uncertainty, thus avoiding future conflicts and potential incidents.
What does forensic engineering consist of?
Forensic engineering is the branch of engineering that investigates failures in industrial products, components or systems by analyzing their causes and consequences, with the aim of identifying their origin and preventing recurrence. This process involves studying material behavior, usage conditions and manufacturing processes, defining hypotheses and evaluating critical variables that may have contributed to the failure.
Unlike approaches based solely on visual inspection or technical documentation, materials forensic engineering relies on results obtained through testing and laboratory analysis. This makes it possible to identify evidence that is not visible to the naked eye, especially in cases where multiple factors are involved or where small deviations in materials or processes can lead to significant failures in final performance.
At INFINITIA, forensic engineering is approached through structured methodologies that combine characterization techniques, experimental testing and simulation of real conditions. This approach allows reconstruction of the failure context, analyzing everything from material microstructure to variables associated with design, manufacturing, assembly or service use.
As a result, it is possible not only to determine what has failed, but to understand why it has occurred and under what conditions, facilitating well-founded decision-making. This analysis allows correction of deviations, establishment of responsibilities when necessary, and definition of effective actions to prevent recurrence in industrial environments where quality and reliability are critical.
Benefits of applying forensic engineering in industry
Forensic engineering makes it possible to address complex industrial problems through the technical analysis of failures whose origin is not evident, providing a solid basis for decision-making. This process involves identifying critical variables related to materials, design, manufacturing or use, evaluating their impact on aspects such as product quality, operational costs or safety.
Unlike approaches based on assumptions or partial information, industrial failure investigation relies on evidence obtained through testing and laboratory analysis. This enables precise identification of the origin of failures such as fractures, deformations, corrosion or degradation, as well as detection of deviations in raw materials or components that may not be evident in technical specifications.
At INFINITIA, this type of analysis is carried out using structured methodologies that combine forensic failure analysis, materials characterization and experimental validation of hypotheses. This approach allows not only evaluation of whether a material or component meets requirements, but also understanding of the technical causes that explain its behavior under real conditions.
As a result, materials forensic engineering makes it possible to resolve discrepancies between involved parties, establish responsibilities when necessary, and reduce uncertainty in decision-making or in legal investigations. It also facilitates validation within root cause analysis processes, contributing to the definition of effective corrective actions and preventing recurrence of failures in demanding industrial environments.
What benefits does Infinitia provide through Forensics Engineering?
At INFINITIA, we approach each forensic engineering project with a decision-oriented mindset, transforming analysis results into clear technical criteria applicable to quality, production or product development.
Our experience across different industrial environments allows us to prioritize the critical variables in each case and act as an integrated technical support, ensuring that conclusions are translated into concrete and actionable solutions.
We develop concrete and actionable technical solutions, based on expertise, testing and experimental analysis, ensuring reliable decisions tailored to each industrial problem.
We approach each project with an external and objective perspective, enabling a scientific-technical analysis of results. This approach helps identify the real root cause of failure, reduce unnecessary iterations and optimize resources.
We work cross-functionally with quality, production, procurement and R&D departments, providing a global view of the problem and its impact on the product.
We apply a methodology based on industrial experience, combined with advanced characterization and failure analysis techniques, ensuring consistent results.
From isolated incidents to complex failures, we adapt the level of analysis and the techniques used to clarify the causes and effects of each situation.
Forensic engineering at INFINITIA
Forensic engineering enables failure analysis in industrial environments where product reliability and evidence-based decision-making are critical. This approach focuses on transforming a failure into useful technical knowledge, identifying key variables related to materials, processes and usage conditions to understand their impact on product performance.
Unlike approaches based on interpretation or partial data, industrial forensic analysis is grounded in results obtained through testing, laboratory analysis and simulations. This enables objective and robust conclusions applicable both to product optimization and to contexts where responsibilities must be established.
At INFINITIA, this type of analysis is carried out using a proprietary methodology that combines expertise in materials and production processes with advanced technologies. This approach integrates characterization techniques, experimental validation and root cause analysis, addressing each case rigorously and according to its complexity.
As a result, industrial failure investigation reduces risk, improves decision-making efficiency and provides key insights for continuous improvement. It also facilitates coordination across different organizational areas, contributing to optimized designs, processes and material selection criteria in demanding industrial environments.
How do we apply forensic engineering in each project?
The application of materials forensic engineering at INFINITIA is based on the combination of different technical capabilities and methods, activated depending on the problem to be analyzed.
This modular approach allows adaptation of the study depth and selection of the most appropriate tools in each case, from failure identification to solution definition.
Below are the main approaches integrated into a forensic engineering project.
Failure analysis
It enables determination of failure mode and cause in materials and components through characterization techniques and experimental validation. Phenomena such as fractures, deformations, degradation or internal defects are analyzed to identify the origin of the problem in production, product or market claims.
At INFINITIA, this analysis forms the foundation of forensic engineering, providing key technical evidence for decision-making and, when necessary, for expert reports.
Quality control and testing laboratory
Physical-chemical, mechanical and functional tests are carried out to evaluate the real behavior of materials and products. These tests can follow international standards or be specifically designed to reproduce service conditions.
This approach allows hypothesis validation within industrial forensic analysis, ensuring conclusions are based on experimental data rather than assumptions.
Reverse engineering
It focuses on characterizing materials, structures and processes to understand how a product is designed and how its components interact. This analysis allows detection of deviations, evaluation of alternatives and understanding of product behavior under real conditions.
Applied within forensic engineering, it facilitates identification of causes related to material selection, formulation or manufacturing processes.
Industrial technical consulting
It consists of interpreting results and defining technical actions based on the analysis performed. This approach allows integration of obtained information into decision-making, whether to correct a problem, optimize a design or define next steps.
At INFINITIA, this phase ensures that analysis goes beyond diagnosis and translates into actionable solutions in industrial environments.
Types of forensic engineering to analyze the origin of industrial failures
In industrial failure analysis, not all problems have the same origin nor require the same technical approach. Forensic engineering is applied through different types of analysis depending on whether the failure is related to the material, the manufacturing process, the service conditions or the interaction between these factors.
At INFINITIA, we combine different forensic engineering approaches in materials, processes and in-service product behavior to adapt each study to the real problem. This approach allows not only the identification of the root cause of the failure, but also an understanding of the key variables involved and how to prevent recurrence in future applications.
Materials forensic engineering
This approach focuses on the analysis of failures in materials such as metals, polymers, ceramics, coatings or multi-material systems, evaluating their composition, microstructure and properties in relation to their behavior in service.
Through advanced characterization techniques, failure mechanisms such as fracture, fatigue, corrosion or degradation are investigated, identifying whether the origin of the problem lies in the material itself, its processing or its interaction with the environment.
At INFINITIA, materials forensic engineering forms the basis of failure analysis, providing objective technical evidence and enabling a precise understanding of the origin of the problem. It is especially critical in products where small variations can significantly affect functionality or durability.
Chemical forensic engineering
This approach focuses on the analysis of raw materials, formulations and chemical products when product performance depends directly on composition or chemical stability.
Using techniques such as chromatography, spectrometry or spectroscopy, it is possible to detect contamination, unwanted reactions, degradation or formulation deviations that may not be evident in technical specifications.
At INFINITIA, chemical forensic engineering allows the identification of causes related to composition or chemical interaction, making it particularly relevant in failures where the origin is not structural, but functional or related to material stability.
Manufacturing process forensic engineering
This approach focuses on analyzing failures that originate during the production process, even when the material or design appear to be correct.
Critical process parameters, manufacturing sequences and interactions between operations are evaluated to identify defects introduced during production that affect final product performance.
At INFINITIA, this approach allows the detection of non-obvious deviations, improving process stability and eliminating recurring failures that cannot be resolved through standard quality controls.
In-service product forensic engineering
This approach focuses on the analysis of products that fail under real operating conditions, where environmental and operational variables differ from laboratory testing conditions.
The failure context is reconstructed based on material evidence, evaluating the influence of load, environment, usage and maintenance on damage evolution.
At INFINITIA, this analysis makes it possible to explain why a product that meets specifications fails in the field, providing key insights to adjust design, validate real conditions and reduce in-service failures.
Industrial forensic engineering
This approach focuses on the analysis of failures in equipment, components and complete industrial systems, evaluating their behavior both during production and under real operating conditions.
Interactions between design, operation and maintenance are analyzed, identifying how system-level variables contribute to failure beyond the individual component.
At INFINITIA, industrial forensic engineering enables the analysis of complex incidents, including accidents, where multiple factors are involved, improving overall system reliability and transforming failures into opportunities for process optimization.
Forensic engineering for claims and technical expert reports
This approach is applied in contexts where it is necessary to determine technical responsibilities in failures or incidents affecting different stakeholders in the value chain.
It combines experimental analysis, materials characterization and process evaluation to generate objective evidence supporting technical conclusions.
At INFINITIA, this approach enables the development of robust and defensible technical reports, providing clarity in conflict situations and supporting data-driven decision-making.
Experimental validation and failure reproduction
This approach is based on the controlled reproduction of failures through tests designed to simulate real operating conditions. It allows validation of hypotheses, isolation of critical variables and confirmation of the root cause through experimental evidence.
At INFINITIA, failure reproduction is a key tool to ensure that proposed solutions are effective, especially in complex or multifactorial problems where conclusions cannot be drawn through theoretical analysis alone.
Industrial sectors where forensic engineering is key to improving quality, reliability and decision-making
Forensic engineering has key applications across a wide range of industrial sectors, as it enables failure analysis, root cause identification and performance improvement of products and systems in environments where reliability and quality are critical. However, materials, production processes and usage conditions vary significantly between sectors, making it essential to adapt the analysis approach to obtain relevant and actionable results.
At INFINITIA, we apply forensic engineering by combining materials characterization, experimental analysis and evaluation of real operating conditions, integrating failure analysis and root cause methodologies. Our objective is to generate technical evidence that allows each problem to be understood in its real context, identify improvement opportunities and support decision-making, contributing to enhanced product quality, reliability and performance across different industrial environments.
Automotive forensic engineering: components subject to fatigue, cyclic loads and real service conditions
In the automotive sector, materials must meet demanding requirements in terms of safety, reliability and resistance to cyclic mechanical loads under real usage conditions. Materials analysis allows the study of steels, light alloys, engineering polymers and joints to understand which variables influence their structural and functional behavior.
- Optimization of joints and assemblies: analysis of welds, adhesive bonding and fastening systems to ensure structural integrity.
- Reduction of in-service failures: identification of fatigue, crack initiation and failure due to repeated dynamic loads.
- Validation of critical components: evaluation of safety-related parts such as shafts, supports or fastening systems.
At INFINITIA, we apply this approach to analyze automotive components, detect differences and define improvements aimed at increasing vehicle safety and reliability. This analysis reduces incidents, optimizes costs and supports data-driven technical decisions.
Energy sector forensic engineering: materials exposed to corrosion, high temperatures and aggressive environments
In the energy sector, materials must withstand demanding conditions such as high temperatures, pressure and exposure to aggressive chemical environments. Materials analysis allows the study of steels, superalloys, protective coatings and multilayer systems to understand the variables that influence their behavior in operation.
- Evaluation of in-service degradation: analysis of corrosion, oxidation and long-term aging under real conditions.
- Optimization of protection systems: study of coatings, inhibitors and surface treatments for harsh environments.
- Failure analysis in critical equipment: evaluation of pipes, heat exchangers or structures exposed to extreme conditions.
At INFINITIA, we apply this approach to analyze energy assets, detect deviations and define improvements aimed at increasing durability and system reliability. This analysis reduces critical failures, optimizes maintenance and supports technical decision-making.
Electronics forensic engineering: materials and assemblies subject to thermal cycling and functional sensitivity
In electronics, materials must meet demanding requirements in terms of stability, conductivity and behavior under thermal and environmental variations. Materials analysis allows the study of solder joints, encapsulations, circuits and functional materials.
- Interconnection diagnostics: analysis of solder joints, electrical contacts and critical connection failures.
- Thermal effects evaluation: study of thermal cycles, heat dissipation and material degradation.
- Manufacturing defect analysis: identification of porosity, delamination or assembly-related defects.
At INFINITIA, this approach is used to analyze electronic systems, detect differences and define improvements aimed at increasing product stability and reliability. It reduces field failures, optimizes design and supports technical decisions.
Construction forensic engineering: incident analysis, structural materials and long-term degradation
In construction, materials must ensure structural strength and durability under environmental exposure and long-term loads. Materials analysis allows the study of concrete, steel, mortars and coatings.
- Evaluation of structural pathologies: analysis of cracking, settlement and progressive degradation.
- Environmental interaction analysis: study of humidity, carbonation or exposure to aggressive agents.
- Execution diagnostics: identification of construction defects or deviations in materials used.
At INFINITIA, this approach is applied to analyze structures, detect deviations and define improvements aimed at increasing safety and durability. It helps prevent failures, optimize interventions and support decision-making.
Consumer goods forensic engineering: materials subject to intensive use, wear and variable conditions
In consumer goods, materials must meet requirements in terms of quality, durability, safety and stability during use. Materials analysis allows the study of plastics, elastomers, technical textiles, coatings or packaging.
- Optimization of materials and formulations: analysis of additives, fillers and processes to improve performance.
- Evaluation of in-use behavior: identification of wear, aging or aesthetic degradation.
- Market product comparison: analysis of differences between commercial solutions or suppliers.
At INFINITIA, this approach is used to analyze market products, detect differences and define improvements aimed at increasing quality and durability. It reduces incidents, optimizes costs and supports data-driven decisions.
Defense forensic engineering: components subject to critical conditions, fatigue and extreme environments
In the defense sector, materials and components must meet demanding requirements in terms of structural integrity, reliability and performance under critical operating conditions.
- Evaluation of high-performance materials: analysis of advanced alloys, composites and systems for critical applications.
- Behavior under extreme conditions: study of fatigue, impact, vibration and degradation in harsh environments.
- Integrity and reliability validation: evaluation of components under high operational demands and strict safety requirements.
At INFINITIA, this approach is used to analyze defense systems and components, detect deviations and define improvements aimed at maximizing reliability and robustness in demanding environments. It reduces risks, optimizes design and supports technical decisions.
Materials forensic engineering at INFINITIA to identify failures and optimize decision-making
Materials forensic engineering makes it possible to transform failures into actionable technical knowledge, precisely identifying the origin of incidents in products, components and industrial systems. At INFINITIA, this service is approached through an evidence-based methodology, where the objective is not only to determine what has failed, but also why it has occurred and under what conditions.
By combining failure analysis, materials characterization and experimental validation, complex incidents involving design, manufacturing and usage variables are investigated. This approach makes it possible to identify damage mechanisms, isolate critical variables and anticipate recurring problems, facilitating the definition of improvements in both product and process.
In addition, forensic engineering has a direct impact on resource optimization. By accurately identifying the root cause, costs associated with rework, claims or incorrect decisions based on unverified hypotheses are reduced. The integration of testing, laboratory analysis and evaluation of real operating conditions improves operational efficiency and strengthens product reliability.
In contexts where decisions have technical, economic or legal implications, this approach provides objectivity and traceability. At INFINITIA, evidence interpretation is carried out from a rigorous technical perspective, enabling coordination across different areas of the organization and the definition of solutions adapted to each case. In this way, forensic engineering becomes a strategic tool for reducing risks and improving industrial decision-making.
Works done in Forensic Engineering
Frequently asked questions about forensic engineering and industrial failure analysis
What exactly is forensic engineering and how does it differ from a conventional technical analysis?
Forensic engineering is the discipline that investigates the origin of failures in materials, components and industrial systems through experimental evidence, not assumptions. Unlike a conventional technical analysis, which may be limited to visual inspection or documentation, forensic engineering integrates the full context of the product: design, manufacturing, conditions of use and environment.
At Infinitia we act as a specialised external technical partner, applying structured methodologies that combine materials characterisation, experimental testing and root cause analysis. The result is an objective and defensible technical diagnosis, not a hypothesis.
→ Find out how we identify the failure mode and cause in each project.
In what situations is it necessary to hire a forensic engineering service?
Hiring forensic engineering is necessary when the origin of a failure is not evident and decisions based on assumptions generate repeated costs or legal risks. The most common situations are:
- Recurring failures in production that cannot be resolved with conventional controls.
- Market claims or returns where responsibilities need to be established.
- In-service incidents where the product met specifications but failed in real use.
- Disputes between manufacturer, supplier or customer requiring objective technical evidence.
- Judicial or expert proceedings where a solid technical report is needed as a basis for the expert’s work.
At Infinitia we have addressed all these scenarios. You can see real examples in our forensic engineering case studies.
What types of failures can industrial forensic engineering investigate?
Industrial forensic engineering can investigate fractures, fatigue, corrosion, plastic deformation, chemical degradation, delamination, adhesive failure, manufacturing defects and failures due to interaction between components. It also covers phenomena such as premature ageing, loss of mechanical properties or contamination in raw materials.
At Infinitia we apply the most appropriate approach depending on the failure mechanism and the material involved, metals, polymers, composites, ceramics or multi-material systems, adapting characterisation techniques to each case.
→ Explore our capabilities in comparative failure characterisation.
How is a forensic engineering analysis carried out step by step?
A forensic engineering analysis follows a structured sequence that starts from the available evidence and culminates in actionable technical conclusions:
- Initial diagnosis: collection of information about the failure, component history and conditions of use.
- Inspection and documentation: visual, photographic and dimensional analysis of the samples.
- Technical hypotheses: formulation of possible causes based on the available data.
- Testing and characterisation: selection of analytical techniques (microscopy, chemical analysis, mechanical testing, etc.) to validate or rule out hypotheses.
- Confirmed root cause: identification of the variable or variables determining the failure.
- Technical report: document with evidence, methodology and conclusions, which can serve as a basis for an expert’s work if the case requires it.
At Infinitia this process is adapted to the complexity of each case. Discover how we approach initial failure diagnosis.
What techniques are used in forensic materials engineering?
Forensic materials engineering uses techniques such as scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS/EDX), infrared spectroscopy (FTIR), chromatography, standardised mechanical testing (tensile, hardness, impact), thermal analysis (DSC, TGA) and non-destructive testing (NDT).
At Infinitia we combine these techniques with root cause analysis methodologies and experimental validation. Unlike a conventional laboratory, our approach as an external technical partner goes beyond executing tests: it includes technical interpretation oriented towards decision-making and the definition of corrective actions.
→ Explore our capabilities in non-destructive testing (NDT) and fractography and microscopy testing.
Can the conditions of a failure be reproduced to confirm its cause?
Yes. Controlled reproduction of the failure is one of the most powerful tools in forensic engineering. It involves designing tests that simulate real conditions of use, load, temperature, environment, cycles, to replicate the product’s behaviour and experimentally validate the hypothesis about the origin of the failure.
At Infinitia we apply this approach when sample analysis is not sufficient to confirm the root cause, especially in multifactorial failures or when it is necessary to demonstrate that a proposed solution is effective before implementing it in production.
→ Find out about our preventive failure analysis service to anticipate future problems.
Why does a material meet the technical datasheet but the product still fails in the field?
A material can meet all the values on its technical datasheet and still fail in the field because specifications do not capture real behaviour under specific conditions of use. Variables such as the combination of loads, operating temperature, interaction with other components, assembly process or environmental conditions can generate damage mechanisms that standard tests do not detect.
At Infinitia we have resolved numerous cases of this type. As an external technical partner, we design tests adapted to the real conditions of the product to identify where theoretical and real behaviour diverge.
→ Explore our accelerated ageing and durability testing capabilities to replicate real service conditions.
Why does the failure keep appearing even though it has already been corrected?
Recurrence of a failure after a correction almost always indicates that action was taken on the visible symptom rather than the root cause. Partial solutions, such as changing a supplier or adjusting a process parameter without prior analysis, can temporarily alleviate the problem without eliminating it.
At Infinitia we do not consider a case closed until the proposed solution has been verified through testing. This criterion, combined with structured root cause analysis, allows us to break the cycle of recurring failures with solutions that work in the long term.
→ Read about recurring failures and how we address them in our article on repetitive production failures.
In which industrial sectors is forensic engineering most critical?
Forensic engineering is especially critical in sectors where a failure has serious consequences for safety, costs or legal liability:
- Automotive: components subject to fatigue, cyclic loads and functional safety requirements (ISO 26262).
- Energy: equipment exposed to corrosion, high temperatures and aggressive environments with impact on operational continuity.
- Electronics and components industry: failures in solder joints, encapsulants and circuits with high functional sensitivity.
- Construction and infrastructure: structural pathologies and materials under CTE or EHE regulations.
- Consumer goods: market claims, product safety and disputes between manufacturer and distributor.
- Defence and aerospace: high-performance components with strict structural integrity requirements.
At Infinitia we have proven experience across all these sectors. See real cases such as the corrosion evaluation in chemical reactors or the failure analysis in factory equipment.
Can forensic engineering help in supplier disputes or insurance claims?
Yes. Forensic engineering is a key tool in commercial disputes and insurance claims because it generates objective technical evidence that determines where and why the failure occurred, and who is responsible.
At Infinitia we produce detailed technical reports combining experimental analysis, materials characterisation and evaluation of the manufacturing process. These reports provide the expert responsible for the case with a solid, traceable and well-documented basis for issuing their opinion, with the rigour required for legal, contractual or insurance contexts.
→ Find out about our industrial benchmarking and comparative testing service when the case involves comparing your own product against external references or competitors.
What is the difference between working with Infinitia and going to a laboratory, technology centre or university?
Accredited laboratories, technology centres and universities are valuable resources and in many cases complementary. Their strengths lie in analytical capacity, regulatory accreditation or research depth. The differentiating factor of working with Infinitia as an external technical partner is different: orientation towards the specific industrial problem and decision-making.
At Infinitia we do not simply execute tests and deliver results: we interpret the evidence in the real context of the product, the process and the sector, and translate it into actionable conclusions. We work cross-functionally with the client’s quality, production, procurement and R&D teams, acting as an extension of the internal team so that the analysis translates into real improvement.
→ Find out how we integrate this approach in our industrial technical consultancy.
How long does an analysis take and how is it budgeted?
The typical timeframe for a forensic engineering analysis is between 1 and 4 weeks depending on the technical complexity of the case. For critical situations, production stoppages, claims with tight deadlines, there is an urgent quotation option that delivers results within 24-72 hours, prioritising the most decisive tests from the outset.
The budget depends on the scope: number of samples, techniques required and whether a formal technical report is needed. At Infinitia we do not carry out unnecessary analyses and always prioritise information with the greatest value for decision-making. After receiving the basic details of the case, we prepare a tailored proposal typically within 24 hours. The first contact is without obligation.
→ Tell us about your case and we will advise you without obligation.
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