Robust or Bust: Designing for Long Term Loading

A product is only as reliable as the data behind its design. While the first step in avoiding failure is a comprehensive product definition, the second is ensuring your material can actually withstand the environment you’ve defined. Many engineers fall into the "datasheet trap"—relying on single-point values that fail to capture how a polymer behaves under real-world stresses, temperatures, and time scales.

Passing short-term testing requirements is no guarantee of long-term durability. For parts subjected to constant or cyclic stress, the most dangerous failures are often the ones that take years to develop. In the third installment of the Robust or Bust webinar series, we dive deep into the science of "Time Under Tension" and the critical mechanisms that govern long-term material performance.

This session focuses on two often-overlooked failure modes: creep—the progressive deformation of a material under constant load—and fatigue—the gradual weakening caused by repeated stress cycles. We will explore the materials science behind these phenomena, identifying why certain materials are inherently susceptible to deformation and which specific properties provide the resilience needed for demanding environments.

Moving from theory to practical application, we will demonstrate how to utilize Finite Element Analysis (FEA) and Time-Temperature Superposition (TTS) to model and predict a product's lifespan. Through a real-world case study, you will see how minor adjustments in part geometry or material selection can dramatically extend a component's durability. Join us to learn how to identify potential risks early and prevent catastrophic, costly failures before they occur.

Key Takeaways:

• The Physics of Failure: A clear breakdown of how creep and fatigue lead to catastrophic collapse in constant and cyclic stress environments.
• Material Selection: Identifying materials with high resistance to long-term loading and understanding the properties that drive that resilience.
• Predictive Modeling: Using FEA and TTS to simulate years of wear and tear in a digital environment.
• Design Optimization: Practical strategies for refining geometry to maximize durability and product lifespan.