Why Material Safety Testing Matters Across Industries
Every product begins with a material. Whether it’s the steel frame of a high-rise or the composite shell of a medical implant, materials form the backbone of modern infrastructure. Even the plastic casing of a consumer gadget relies on material integrity, which we often take for granted. Yet too often, their safety is assumed, not verified.
Material safety testing is not merely a procedural requirement. It’s a proactive safeguard that can mean the difference between success and systemic failure. It can separate public trust from global recall and lives saved from lives lost.
This article explores why material safety testing is vital and how different industries are impacted by it. It also highlights the legal, financial, and human consequences of getting it wrong.
The Hidden Risks in Everyday Materials
Materials may appear solid and stable, but under the surface, their properties can change with exposure to temperature, pressure, moisture, or chemicals. Corrosion, fatigue, leaching, and structural degradation are all phenomena that can cause a once-dependable material to fail unexpectedly.
Industries today use complex materials in increasingly sophisticated ways. Examples include polymer-based medical devices, corrosion-resistant alloys in factories, food-grade containers, and fire-retardant building materials. With this complexity comes responsibility: to ensure those materials are not only functional but safe under real-world conditions.
In the sections below, we’ll explore the most critical industries where material testing plays a vital role in ensuring safety.
Chemical and Manufacturing Plants
From high-pressure pipelines to chemical reactors and containment vessels, industrial equipment must endure exposure to extreme pH levels, heat, vibration, and toxic fumes. Even small weaknesses can lead to explosions, leaks, or contamination events.
Case in Point: Plant Shutdown Due to Corrosion
A relevant example is Fulcrum BioEnergy’s waste-to-fuel gasification plant near Reno, Nevada. This pioneering facility aimed to convert municipal solid waste into sustainable aviation fuel but encountered significant operational hurdles.
The plant suffered from nitric acid corrosion that damaged critical equipment. Additionally, a cement-like substance built up in the gasification system, obstructing operations and causing costly delays.
These problems highlighted the importance of comprehensive material safety testing and pilot-scale validation before full-scale deployment. Ultimately, the persistent issues led to the plant’s shutdown. This highlights the need for industrial operations to carefully assess material compatibility and maintain strong contingency plans to avoid downtime and losses.
Healthcare and Medical Devices
The healthcare industry demands the highest safety standards. Materials used in implants, catheters, and surgical tools must endure prolonged exposure to bodily fluids, fluctuating temperatures, and mechanical stress. They must do so without breaking down, leaching chemicals, or causing infections.
Real-World Example: Bard Power Port
The Bard Power Port, a catheter device implanted to deliver medication, has recently come under scrutiny. According to TorHoerman Law, thousands of lawsuits allege that the device’s polyurethane catheter tubing degraded over time. This degradation led to catheter fractures, device migration, and severe bloodstream infections.
As of June 2025, Drugwatch reports that about 1,500 lawsuits are actively pending in Arizona. These cases are part of a multidistrict litigation, highlighting the widespread impact of the issue.
While the Bard Power Port lawsuit is making headlines, it’s not the first or last of its kind. Similar lawsuits have occurred over mesh implants, hip replacements, and even surgical gloves. These cases highlight the high cost of inadequate material testing and oversight in medical manufacturing.
Construction and Infrastructure
Bridges, roads, tunnels, and high-rises all rely on materials like concrete, steel, and composites. Failures in this sector are often catastrophic and make national headlines.
Notable Mention: The Tretten Bridge Collapse (Norway, 2022)
The 2022 collapse of Norway’s Tretten Bridge shocked many. Designed to last 100 years, this timber and steel truss bridge gave way after only ten years in service. Investigations revealed that a rushed construction timeline, reuse of old foundations, and a strong focus on aesthetics over durability compromised the structure’s strength.
Timber, while sustainable and visually appealing, was not adequately tested or monitored for long-term wear under these conditions. Over time, one of the key timber supports suffered block shear failure, weakening the bridge until it suddenly collapsed.
This incident highlights the critical need for rigorous material safety testing and continuous monitoring. Even attractive, well-intended designs can fail catastrophically without proper attention to material performance and durability.
Food and Beverage Industry
In food processing, materials in contact with consumables must be tested for leachables, chemical stability, and microbial resistance. Plastic tanks, metal piping, and even seals and gaskets must be compliant with food-grade standards.
An example? In April 2025, nearly 18,000 ice cream and frozen yogurt products were recalled across the U.S. due to potential plastic contamination. The voluntary recall, issued by Iowa-based Wells Enterprises, impacted 22 brands, including popular names like Blue Bunny, Bomb Pops, and Halo Top. The affected products were distributed from over 100 centers nationwide.
Regular chemical migration testing could have helped manufacturers prevent such large-scale recalls and protect consumer safety.
How Material Testing Saves Lives and Bottom Lines
Here’s what rigorous material testing can prevent:
- Legal Liability: Companies like Bard, 3M, and Johnson & Johnson have paid billions due to product failures linked to material issues.
- Operational Downtime: Unplanned equipment failure from untested materials can lead to costly plant shutdowns.
- Environmental Damage: Leaks from corroded tanks or pipes can contaminate soil and groundwater, triggering fines and community backlash.
- Brand Erosion: One safety scandal can destroy decades of brand trust.
Testing parameters typically include:
- Tensile and compressive strength
- Corrosion resistance (e.g., salt spray tests)
- Chemical compatibility
- Leachability and migration potential
- Thermal stability and flammability
- Degradation over time
FAQs:
Rising temperatures, increased humidity, and acid rain can accelerate material degradation. These climate shifts may compromise the durability of construction materials, piping systems, and outdoor electronics. This makes it essential to test materials under future climate simulation conditions.
Absolutely. In wind turbines, solar panels, and EV batteries, material failure can lead to energy loss, overheating, or reduced lifespan. Testing ensures that these sustainable technologies perform efficiently and safely across a wide range of temperatures, weather conditions, and varying electrical loads. This helps maintain their reliability and longevity over time.
Different countries have varying regulations and testing protocols based on local environmental factors and industrial practices. Understanding and complying with these regional standards is critical for manufacturers aiming to enter global markets and avoid costly recalls or legal issues.
Overall, in a world where innovation is speeding up and regulatory scrutiny is tightening, material testing is no longer optional. It’s a necessity for protection, compliance, and conscience.
The next time you look at a product, whether it’s a valve, a port, or a plastic bottle, pause for a moment. Ask yourself: Has this material truly been tested for where it’s going? If the answer is no, it’s time to start asking tough questions.