Product Liability and Electrical System Failures: Insights from an Electrical Engineer Expert Witness

When electrical or electronic products fail, the consequences can be severe—ranging from fires and injuries to widespread equipment damage. In product liability cases, determining whether the failure resulted from a design flaw, a manufacturing defect, or improper use is critical to establishing legal responsibility. At Discovery Engineering, we bring deep technical knowledge and years of hands-on experience as electrical engineer expert witness professionals to support litigation involving product failures.

What Is Product Liability in Electrical Engineering?

Product liability refers to the legal obligation of manufacturers, designers, or sellers to ensure that their products are safe for use. In the context of electrical system failures, this could involve a range of consumer, commercial, or industrial devices—from control panels and appliances to surge protectors and battery systems.

A successful legal claim requires technical clarity: was the product inherently dangerous due to a poor design? Did the manufacturing process introduce defects? Was the product used in a way not intended by the manufacturer, and was that foreseeable?

Discovery Engineering provides expert witness services that help legal teams answer these questions with engineering precision.

Common Electrical Failures in Product Liability Cases

Several recurring issues often form the basis of product liability claims in the electrical domain:

• Design flaws that result in excessive heat generation, short circuits, or arc faults
• Improper component selection, especially in control panels not meeting UL 508A standards
• Inadequate surge protection, despite a product’s claim of UL 1449 compliance
• Misuse of UL Recognized components where UL Listed components are required
• Overlooked arc flash risks due to misapplied or outdated calculations, which are addressed in the revised IEEE 1584-2018 standard

Each of these failure modes requires in-depth analysis to determine root cause, which is where Discovery Engineering’s failure analysis and code compliance expertise play a central role.

Engineering Standards That Shape Liability

Evaluating the safety and reliability of an electrical product requires reference to established standards. These frameworks help define what a “reasonably safe” product looks like and whether the manufacturer met those obligations.

NFPA and the National Electrical Code (NEC)

The NFPA publishes the NEC, which governs safe electrical installations. While the NEC primarily applies to installation work, many of its principles—such as overcurrent protection, grounding, and conductor sizing—also influence safe product design. Products that fail to conform to these safety principles may contribute to fire or shock hazards and thus expose manufacturers to liability.

IEEE 1584 and Arc Flash Hazards

Arc flash is one of the most serious risks in electrical products and equipment. The IEEE 1584-2018 standard provides the most current and comprehensive method to calculate arc flash incident energy. It takes into account various system configurations, enclosure dimensions, and busbar arrangements.

A product that does not account for these hazards—especially in switchgear, distribution panels, or high-power electronics—may endanger users and open the door to legal action if injuries occur.

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UL 1449 and Surge Protection

UL 1449 is the key safety standard for surge protection devices (SPDs). While the UL mark ensures that a product has been tested for safety under a standard transient, it does not guarantee high performance under all real-world conditions—particularly in industrial environments with frequent switching transients.

In litigation, Discovery Engineering analyzes the suitability of SPDs, inspects whether the UL classification was properly applied, and determines whether the device’s failure contributed to the incident.

UL 508A and Control Panels

UL 508A covers the design and assembly of industrial control panels. It defines which components are acceptable, how they must be installed, and what labeling is required. A panel assembled with unlisted or incorrectly installed components—even if it functions under normal conditions—can pose severe safety risks under fault conditions.

If a fire or malfunction occurs, we determine whether the panel complied with UL 508A and whether the assembly contributed to the product’s failure.

Role of Failure Analysis in Legal Cases

When an electrical product causes damage or injury, identifying the precise failure mechanism is the key to determining liability. Discovery Engineering conducts thorough failure analysis to determine whether:

• The product’s design had inherent safety flaws
• Manufacturing processes introduced defects (e.g., poor solder joints, faulty insulation)
• Components failed due to overvoltage, thermal stress, or improper specification
• The product was misused, and whether that misuse was foreseeable

We then compare these findings against product liability standards and codes, translating complex engineering into language that courts and juries can understand.

Expert Witness Services That Support the Legal Process

At every phase of litigation—from discovery to deposition to trial—Discovery Engineering serves as a trusted electrical engineer expert witness. Our work includes:

• Reviewing design documentation and product specifications
• Conducting root cause failure analysis
• Evaluating compliance with UL, NEC, IEEE, and NFPA standards
• Writing expert reports that withstand scrutiny under Daubert and Frye
• Delivering clear, confident testimony in deposition and trial

We also collaborate with forensic investigators where needed, especially when physical evidence must be preserved and tested in a lab setting.

Why Discovery Engineering?

Litigation involving electrical product failures requires more than theoretical knowledge. You need real-world experience, a deep understanding of safety standards, and the ability to communicate findings clearly. Discovery Engineering offers:

• Decades of engineering and field experience
• Direct familiarity with industry standards like UL 1449, IEEE, NFPA, and NEC
• Litigation-ready support with clear, defensible reporting

Our mission is to bring technical clarity to complex legal challenges, ensuring that the cause of a failure is properly understood and that responsibility is appropriately assigned.

Product Liability from a Chain of Technical Missteps

Product liability cases involving electrical components are rarely simple. Whether it’s a consumer product, a control system, or an industrial panel, failure often stems from a chain of technical missteps. Identifying and explaining those missteps requires a combination of engineering expertise and legal awareness.

Discovery Engineering is here to provide that clarity. If you’re involved in a product liability case where electrical system failures may be to blame, reach out to our team today for expert witness support that delivers results.