16 Items That Failed Testing
By Ace Vincent
| Published 25 seconds ago
When manufacturers rush products to market or cut corners on safety checks, the results can be catastrophic. From household items to vehicles, products that fail testing often end up causing injuries, deaths, or massive financial losses before being recalled. These failures remind us that rigorous testing isn’t just bureaucratic red tape—it’s the difference between a useful product and a dangerous one.
Testing failures happen across every industry imaginable, affecting millions of consumers worldwide. Here is a list of 16 items that failed testing and caused significant problems before being pulled from shelves or redesigned.
Ford Pinto
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Ford’s compact car from the 1970s became infamous for its rear-end collision design flaw. The fuel tank was positioned too close to the rear axle, making it prone to rupture and catch fire in crashes.
Internal Ford documents revealed the company knew about the problem but calculated that paying wrongful death lawsuits would cost less than fixing the design.
Takata Airbags
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These airbag inflators were used by virtually every major automaker on the planet until they started exploding unpredictably. The inflators can explode and eject a shrapnel-like material that has been linked to at least 20 deaths.
The defective inflators affected over 100 million vehicles worldwide, making it one of the largest automotive recalls in history.
Samsung Galaxy Note 7
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Samsung’s flagship smartphone turned into a pocket-sized fire hazard when its lithium-ion batteries began overheating and catching fire. The phones were banned from airlines and caused evacuations of entire flights.
Samsung eventually discontinued the model entirely and recalled all 2.5 million units after multiple incidents of phones literally exploding in users’ hands.
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Chevrolet Corvair
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Ralph Nader’s book “Unsafe at Any Speed” helped expose the Corvair’s dangerous handling characteristics. The rear-engine design made the car prone to sudden oversteer, causing it to flip during routine turns.
GM knew about the handling problems but chose not to install a stabilizer bar that would have cost just $15 per vehicle.
Firestone 500 Tires
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These steel-belted radial tires had a tendency to separate at highway speeds, causing vehicles to lose control and crash. The problem stemmed from poor bonding between the steel belts and rubber, but Firestone continued selling them for years.
The recall eventually covered 10 million tires after hundreds of accidents and dozens of deaths.
Rely Tampons
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Procter & Gamble’s super-absorbent tampons were linked to a surge in toxic shock syndrome cases in the early 1980s. The synthetic materials used in the tampons created an ideal environment for bacteria to grow and produce toxins.
The company pulled the product from shelves after reports connected Rely tampons to 38 deaths.
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Tylenol Cyanide Murders
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While not technically a manufacturing defect, the 1982 Tylenol poisonings exposed how vulnerable over-the-counter medications were to tampering. Someone laced bottles with potassium cyanide, killing seven people in the Chicago area.
The incident led to the development of tamper-resistant packaging that we still use today.
Peg Perego Baby Products
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The Italian company’s 3-in-1 recliners, swings, and high chairs failed multiple federal safety standards. The 3-in-1 products pose a suffocation risk because they were marketed for infant sleep, and they have an incline angle greater than 10 degrees, which increases the risk of positional asphyxia in infants.
Infantino Baby Slings
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Approximately 1 million Infantino baby slings are being recalled due to breathing hazards that arise from the product’s design. The fabric could press against a baby’s nose and mouth, restricting airflow.
At least 14 deaths were linked to these slings before the recall, with most victims being infants under four months old.
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Hallmark/Westland Beef
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Hallmark/Westland went bankrupt following an investigation into animal cruelty that led to a massive recall of more than 143 million pounds of beef. Hidden camera footage revealed workers using cruel methods to force sick cattle to walk, violating food safety regulations.
Much of the meat had already been served in school lunch programs across the country.
Pet Food Contamination
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The 2007 pet food recalls involved the massive recall of many brands of cat and dog foods beginning in March 2007. The recalls came in response to reports of renal failure in pets consuming mostly wet pet foods made with wheat gluten from a single Chinese company, beginning in February 2007.
Over 5,000 pets died from kidney failure caused by melamine contamination.
Three-Wheeler ATVs
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All-terrain vehicles with three wheels were banned from production in 1988 after causing over 900 deaths. The design was inherently unstable, with the single front wheel making it easy to flip over backward during acceleration or forward during braking.
Manufacturers agreed to stop making them and focus on four-wheel designs instead.
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Lawn Darts
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These heavy, metal-tipped projectiles were marketed as backyard games but proved deadly when thrown. The sharp points could penetrate skulls and cause fatal brain injuries, particularly in children.
After a father whose daughter was killed by a lawn dart lobbied for a ban, the Consumer Product Safety Commission prohibited their sale in 1988.
Fisher-Price Rock ‘n Play
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This infant sleeper was recalled after being linked to over 100 deaths, mostly from suffocation. Babies could roll from their backs to their stomachs while in the device, but the soft padding and inclined design made it difficult for them to breathe.
The company marketed it as safe for overnight sleep despite knowing the risks.
Bridgestone/Firestone Wilderness Tires
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These tires, often paired with Ford Explorers, had a tendency to shed their treads at highway speeds. The combination of the tire’s design flaws and the Explorer’s high center of gravity led to numerous rollover accidents.
Over 270 deaths were linked to these tire failures before the massive recall and redesign.
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Exploding Pinto Gas Tanks
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Beyond the collision problems, early Ford Pintos also suffered from fuel filler neck issues that could cause gas tanks to explode during filling. The design allowed fuel vapors to accumulate and ignite from static electricity or other sources.
Ford eventually redesigned the filler system, but not before several gas station explosions injured customers and attendants.
When Testing Becomes Critical
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These product failures demonstrate that adequate testing isn’t just about meeting minimum standards—it’s about anticipating real-world use and potential misuse. Companies that prioritize speed to market over thorough testing often end up facing massive lawsuits, damaged reputations, and sometimes criminal charges.
The most successful recalls are those where companies acted quickly once problems were discovered, rather than trying to cover up or minimize the issues.
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