Adhesives, Sealants & Industrial Bonding worked example

Bond Failure Cost at 61% adhesive-attributable failure share: a worked example

Suppose adhesive-attributable failure share falls to 61%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate financial exposure from bond failures using failed assemblies, failure cost, attributable share, and containment charge.

The inputs for this scenario

  • Failed bonded assemblies: 9 assemblies (held at the documented default)
  • Cost per bond failure: 420 $ / failure (held at the documented default)
  • Adhesive-attributable failure share: 61 % (the input this scenario stresses; the baseline uses 85)
  • Containment/investigation charge: 950 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Adhesive-attributable failure cost = failed assemblies × cost per failure × attributable share.
  • Bond failure cost exposure works out to 3,256 $ failure at these inputs, and this is the headline figure for the scenario.
  • Cost per bond failure works out to 362 $ / failure at these inputs.
  • Adhesive-attributable failure cost works out to 2,306 $ failure at these inputs.
  • Containment/investigation charge works out to 950 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where adhesive-attributable failure share sits at 85% and the headline result is 4,163 $ failure, this scenario comes in 21.79% below the baseline at 3,256 $ failure.
  • It computes total bond failure cost exposure by pricing the adhesive-attributable portion of failed assemblies and adding the containment and investigation charge. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Bond failure cost exposure: 3,256 $ failure (headline result)
  • Cost per bond failure: 362 $ / failure
  • Adhesive-attributable failure cost: 2,306 $ failure
  • Containment/investigation charge: 950 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Bond Failure Cost calculator, set adhesive-attributable failure share to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.