Product Defect & Failure Analysis

Product Defect & Failure Analysis

Visualizing the invisible. Uncovering the truth.

At 4ensic Impact LLC, we help uncover the root causes of product failures using advanced imaging and visualization techniques. Working alongside laboratory partners, we conduct non-destructive internal inspections and convert data into clear, courtroom-ready exhibits.

When product integrity is in question — whether it’s a design flaw, a manufacturing defect, or a material failure — we provide the analysis and visuals needed to demonstrate exactly what went wrong, and why.

Structured Light & CT Scanning

We collaborate with certified labs to obtain high-resolution scans of consumer products, industrial components, and mechanical assemblies.

• Structured light scanning creates detailed surface geometry and dimensional accuracy, ideal for visualizing external features and component alignment.

• CT scanning reveals internal structures without disassembly, allowing us to inspect welds, voids, fractures, or assembly errors hidden inside the object.

Non-Destructive Internal Inspection

No need to cut open or destroy the product.Using scan data, we generate 3D volumetric visualizations that allow attorneys, experts, and jurors to “see inside” the product and examine how it was assembled, how it failed, and what should have happened.

This approach preserves evidence while making internal failures understandable and credible.

Volumization & Defect Identification

We go beyond raw scans.Our team processes and interprets the data, creating annotated visuals and simulations that identify:

• Cracks, porosity, and structural weaknesses

• Incomplete bonding, separation, or foreign objects

• Manufacturing inconsistencies or deviations from spec

• Wear and stress failure points

Support for Defect Litigation

Whether you're litigating a product liability claim, a construction defect, or an industrial equipment failure, we provide the visuals and expert context to support your case.

Our deliverables can include:

• Comparison visuals between as-designed and as-manufactured parts

• Failure sequence animations

• Layered cross-sections and exploded views

• Technical boards for depositions or trial presentation