Failure reproduction
Failure reproduction is a specialized service that makes it possible to simulate, in a controlled way, the failure mechanisms that can occur in industrial materials, components, or systems.
At INFINITIA Industrial Consulting, we approach this service from a scientific and technical standpoint, with the goal of validating hypotheses about failure causes through accelerated testing.
Thanks to our industrial laboratory, equipped with state-of-the-art technology and a multidisciplinary team with extensive experience in materials analysis, we develop specific tests that reproduce real or extreme service conditions.
This makes it possible to understand the origin of a failure, evaluate alternative materials, and optimize production processes. At INFINITIA, we do not just generate valuable technical information; we deliver concrete solutions through a rigorous methodology, tailored to each case and to the needs of the industrial client.
Talk to a specialist
Request a free initial consultation; contact a consultant from our team of specialists
What does failure reproduction involve?
What is it?
Failure reproduction involves designing and carrying out a set of technical tests that make it possible to simulate, under controlled conditions, the behavior that triggers a failure previously observed in a product or component.
This service is key within failure diagnosis processes, as it makes it possible to verify whether a hypothesis is valid by reproducing the problem under the same use, stress, or degradation parameters (among others).
At INFINITIA, we carry out this reproduction using techniques such as accelerated aging in climate chambers, exposure to salt spray, abrasion testing on abrasion testers, thermal testing with climate chambers, and analysis of chemical resistance or bacterial overgrowth.
Each test is designed according to the type of failure being studied, and can be complemented with characterization techniques such as FTIR, optical microscopy, or SEM-EDS to identify microdamage or alterations in the material structure.
This methodological flexibility allows us to adapt our approach to different sectors and types of product.
How we carry out the service at INFINITIA
At INFINITIA, failure reproduction is carried out within our industrial laboratory, combining knowledge from forensic engineering, materials science, and functional analysis.
We have specific equipment for accelerated testing, climate chambers, salt spray systems, abrasion equipment, thermal stations, and advanced microscopy.
Our process begins with a technical meeting with the client to define initial hypotheses, after which we design the testing plan, which includes simulated service conditions, validation criteria, and complementary characterization techniques.
Based on the results, we propose viable alternatives that can be subjected to comparative testing. All work is documented in accordance with applicable technical standards and can be integrated into root cause analysis (RCA), 8D studies, or corrective action plans.
At INFINITIA, we do not just reproduce the failure; we turn it into applicable knowledge to improve the client’s processes.
Key benefits and advantages
Benefits
The main benefit of failure reproduction is the ability to objectively and empirically validate failure causes, which reduces diagnosis time and improves decision-making in quality, design, or production processes.
This approach also allows the industrial client to evaluate possible material or design alternatives under the same failure conditions, resulting in optimized durability, performance, and cost of the final product.
At INFINITIA, we have reproduced failures such as premature oxidation, thermal degradation, friction-related failures, or chemical incompatibility issues, helping our clients redesign processes, select new materials, or modify service conditions to prevent recurrence.
The ability to reproduce the failure also facilitates comparative testing between suppliers or production batches, reinforcing quality control and increasing product reliability in the market.
Types of Failure Reproduction Testing
types
At INFINITIA Industrial Consulting, we develop different failure reproduction tests to evaluate and simulate the failure mechanisms of industrial materials, components, and systems.
Our goal is to reproduce failures under controlled conditions and understand their origin in order to optimize the performance, safety, and service life of products. Below, we detail the types of tests we carry out to simulate failures and how each one contributes to improving design or process.
Accelerated aging testing
This testing makes it possible to simulate the wear and degradation of materials and components under extreme temperature and humidity conditions. At INFINITIA, we use climate chambers and salt spray to accelerate the effects of time, reproduce failures such as oxidation or moisture-related deterioration, and predict material behavior over its life cycle.
For example, we have used this testing to simulate the degradation of metal coatings on components exposed to adverse conditions, helping to select the best material resistant to corrosion.
Failure characterization through microscopy and fractography
Abrasion testing makes it possible to simulate the impact and friction that materials are subjected to during use. At INFINITIA, we use abrasion testers to carry out wear tests that replicate working conditions such as those that could cause failures in surfaces or moving parts.
This testing is essential in sectors such as automotive, where components must withstand friction wear and maintain their functional integrity. For example, in an automotive project, we assessed the wear resistance of plastic components subjected to repetitive friction conditions.
Thermal and overheating testing
Thermal and overheating testing replicates material failure due to temperature variations. We use climate chambers and thermal stations to expose materials to rapid temperature changes, simulating thermal failures such as polymer degradation or thermal fatigue in metals.
At INFINITIA, we have carried out testing on electronic and electrical materials to simulate and reproduce thermal failure and improve the durability of electronic components under extreme temperature conditions.
Chemical resistance testing
This testing makes it possible to simulate how materials behave against chemical attack that can cause failures, such as oxidation, corrosion, or chemical degradation. At INFINITIA, we carry out analysis using FTIR, optical microscopy, and SEM-EDS to study the chemical resistance of materials to various reagents.
A recent case involved simulating failures in plastic coatings exposed to aggressive chemical products, helping to improve the chemical resistance of materials used in the automotive industry.
Bacterial overgrowth testing
In some sectors, bacterial overgrowth failures can compromise the functionality of a product. This type of testing is key in validating materials for medical, pharmaceutical, or food applications. At INFINITIA, we use microbiological techniques to reproduce bacterial growth failure on surfaces or materials in contact with pathogenic organisms.
One example of this is failure simulation in materials, where we analyzed resistance to bacterial growth, thereby preventing potential failures under real conditions.
Applications of failure reproduction
sectors
Failure Reproduction with INFINITIA
Value
At INFINITIA Industrial Consulting, failure reproduction is a core service for thoroughly understanding failures that can occur in industrial materials, components, and systems. Through accelerated testing, failure simulations, and comparative analysis, we help our clients identify the root causes of problems and validate hypotheses on how to prevent future failures. This approach makes it possible not only to optimize product design, but also to improve the durability, reliability, and safety of materials used in the most demanding sectors.
Our experience in forensic engineering allows us to go beyond superficial diagnosis. At INFINITIA, we carry out customized testing based on the specific conditions of each client and product, adapting our simulation methods to the particular needs of each industry. Whether through accelerated aging, thermal testing, abrasion testing, or chemical failure simulations, our goal is to offer solutions that minimize risk and maximize the reliability of final products.
In a world where innovation and quality are decisive for success, having a strategic partner like INFINITIA for failure reproduction can make the difference. The benefits of carrying out this testing include better resource management, materials optimization, and, most importantly, failure prevention that could otherwise affect the safety, functionality, and reputation of products. Future trends point toward increased testing personalization, greater integration of digital technologies to monitor and model failures, and process optimization.
