Polymers & Materials Used for Consumer Electronics

A close up view of a row of solid state batteries

Thought leadership

Solid-State Battery Hype & Intellectual Property

Make informed decisions regarding the polymers and materials used in consumer electronics.

The demand for the latest trends in electronic technologies continues to drive the consumer market. Manufacturers benefit from conducting due diligence when choosing materials, with an eye on consumer safety and environmental sustainability. Protecting and validating trade and intellectual property at every step of the product lifecycle is also critical — and when issues of warranty or recall arise, clients turn to Exponent for strategic guidance and support.

How does our multidisciplinary approach to consulting benefit you?

Exponents' multidisciplinary experts leverage expertise in polymer manufacturing and custom chemical testing to provide cost- and time-effective analysis of polymers, paints, coatings, adhesives, and thin films used in a wide array of consumer electronic devices.

Our teams assist clients with the design, manufacture, and reliability of new electronic products and with assessing material selection, compatibility, failures, warranties, and recalls.

We implement lessons learned from our 50+ years of conducting failure analysis to bring our clients essential insights grounded in proven scientific methods and provide strategic support for issues of intellectual property.

Our experts support factory audits, and the development of in-line or incoming quality control tests, and we also routinely conduct field failure investigations. We address client concerns related to all aspects of product development as well as important issues involving the health of staff, customers, and the environment.

Capabilities & Services

Our multidisciplinary approach assists clients in evaluating polymer and material performance in consumer electronics.

Exponent's multidisciplinary teams have extensive experience consulting on adhesives used in a broad range of applications and industries, including optically clear adhesives, conductive epoxies, heat-activated films, sealants, caulks, adhesive bonding failures, cure or process optimization, and more. We conduct assessments to evaluate the human and occupational risks associated with these materials, as well as rigorous tests on all types of consumer electronics to provide clients with detailed analyses of their adhesive products and performances. When product failures occur, we help with remediation decisions, as well as end-use product stewardship strategies.
Polymer fractures in consumer electronics can lead to product recalls, accident investigations, or legal disputes. Exponent's multidisciplinary approach to polymer science, materials chemistry, materials & corrosion engineering, mechanical engineering, and statistical & data sciences provides strategic evaluation and analysis of polymer fractography, as well as degradation and stability in additive manufacturing. These insights are critical to informing decisions throughout the entire product lifecycle.
Exponent's experts have extensive experience in studying and advising clients on the structure-property relationships and processing of polymeric systems. We consult on the development, formulation, scale-up, quality testing, and large-scale industrial manufacturing of polymer/plastics, and we assist clients in all stages of product life — from product development to end-use evaluation and long-term field performance.
Our experts provide deep understanding of the chemistry, physical properties, and mechanical behavior of polymeric materials, including rubbers, elastomers, adhesives, and rigid plastics. We assist clients with durability assessments, materials specifications, formulation, end-use testing, product safety evaluations, and failure analysis in both proactive and reactive programs in a wide variety of industries, including automotive, consumer electronics, construction, medical, and industrial piping. We commonly address rubber failure modes, including wear and tear, environmental stress cracking, fatigue, creep, and weathering that can occur across types of consumer electronics and their accessory devices.
Exponent leads the consulting industry in helping consumer electronics manufacturers make informed decisions regarding lithium-ion batteries. Our capabilities span the entire product lifecycle including battery design reviews, battery safety and storage, quality safety assessments, risk assessments and corrective actions, battery safety and recall support, battery supply chain services, battery recycling, and product stewardship initiatives. Our experts use Exponent's state-of-the-art testing and disassembly laboratory services for design, testing, and recall assessments of all lithium-ion batteries used in a variety of consumer electronics.
When globally distributed manufacturers operate in Asia, they rely on Exponent's Hong Kong Laboratory Services to conduct rigorous testing and examination of their products. Exponent creates extraction and leachable protocols and develops toxicological risk assessments, assists in contamination analysis and de-contamination protocol development, advises on battery safety, and conducts risk assessments and failure analysis for all types of consumer electronic products.
Electronics manufacturing comes with its fair share of waste and byproducts, which must be properly disposed. Furthermore, with each new iteration of technology comes the potential for increased waste products as end-users upgrade and discard older electronics. Exponent guides clients through the development of environmental stewardship initiatives spanning the entire product lifecycle, including design, manufacturing, distribution, and end-of-life recycling and reuse. Our multidisciplinary teams have extensive experience in environmental and ecological sciences — and in-depth knowledge of U.S. and EU environmental regulatory and compliance standards — and provide regulatory expertise in full lifecycle product management, helping clients to develop sustainable recycling strategies for all polymer and plastic products.
At a glance, our consumer electronics consultants in Polymer Science and Materials Chemistry offer the following services:
- Product testing and quality compliance
- Manufacturing and processing support
- Material selection and compatibility
- Third-party auditing, including engineering audits, vendor evaluation, manufacturing line failure analysis, and improving yields and efficiency
- Product warranty and recall support
- Risk and failure analysis
- Evaluation of battery performance and add-ons
- Regulatory compliance support (U.S. and international)
- Patent protection and infringement evaluations
- Independent design and packaging evaluations
- Insurance, environmental, or health claims investigations
- Litigation support and expert witness testimony
- Hardware and software consulting support
- Assessments of health and environmental risks before products enter the stream of commerce

Our Capabilities Are Unparalelled

With expertise in over 90 disciplines and hundreds of capabilities, tools, and methodologies — we get to the root of even the most complex challenges and give you the objective answers you need.

A worker pours a bag of polymer beads into a manufacturing machine. Exponent provides engineering expertise for polymers and plastics.

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Our global and comprehensive expertise across industries gives us a deep understanding of current challenges, best industry practices, and the implications of emerging technologies.