General

1. What industries does The Madison Group specialize in?

We provide expert consulting across a wide range of sectors, including Medical, Automotive, Consumer, Industrial, and Packaging. Our focus is on any application where plastic performance and reliability are critical to the product’s success.

2. Do you only work with plastics, or do you handle metals and composites as well?

Our expertise is exclusively dedicated to polymers—including plastics, rubbers, elastomers, and advanced composites. While we analyze how these materials interact within multi-material assemblies, our investigations and testing services are focused solely on the performance, design, and failure of the polymer components.

3. What is the typical turnaround time for a project?

Turnaround varies by complexity. Standard material testing (like FTIR or DSC) can often be completed in 5-7 business days. Comprehensive failure investigations or full-scale FEA design projects typically range from 1 to 2 weeks, depending on the depth of analysis required.

4. Are your engineering services available globally, or only in North America?

We serve a global client base. While our headquarters is in the United States, we regularly consult for international manufacturers and provide litigation support and technical training for firms worldwide.

Technical Services & Capabilities

5. What types of material testing do you perform in-house?

Our laboratory is equipped for comprehensive polymer characterization. We perform:

• Thermal Analysis: DSC (Differential Scanning Calorimetry), TGA (Thermogravimetric Analysis), and DMA (Dynamic Mechanical Analysis).
• Compositional Analysis: FTIR (Fourier Transform Infrared) spectroscopy and EDS (energy dispersive X-Ray spectroscopy) to characterize unknown materials or contaminants.
• Mechanical Testing: Tensile, flexural, compression, creep and fatigue testing under various environmental conditions.
• Microscopy: Digital and Scanning Electron Microscopy (SEM) for fracture surface imaging.

6. Can you help with material selection for a new product design?

Yes. Choosing a material based solely on a data sheet often leads to field failures. We evaluate the “Performance Triangle”—the relationship between the material, the part design, and the manufacturing process—to ensure the polymer can withstand its specific end-use environment, including chemical exposure and long term mechanical loading.

7. What information do I need to provide for a failure analysis investigation?

To provide a definitive root cause, we typically need:

• The failed part (and a “control” or unbroken part if possible).
• A description of the service environment (temperature, chemicals, load).
• The estimated time to failure.
• Processing logs or material certifications.
• Note: Please do not clean the fracture surface, as this can destroy critical microscopic evidence.

Consulting & Design

8. At what stage of the design process should I involve The Madison Group?

Ideally, during the Concept and Design phases. By involving us before tooling is cut, we can help you optimize material selection and part geometry, potentially saving tens of thousands of dollars in re-tooling costs and preventing future field failures.

9. Do you provide litigation support or expert witness services?

Yes. Our senior engineers have extensive experience providing expert testimony for product liability cases. We provide data-driven, objective technical analysis that stands up to the rigors of the courtroom.

10. How do you handle Intellectual Property (IP) and confidentiality?

Confidentiality is a cornerstone of our business. We work with highly sensitive proprietary designs and are happy to sign Non-Disclosure Agreements (NDAs) before reviewing your project details. Your data and samples are stored in a secure, controlled environment.

11. Can you help troubleshoot manufacturing defects like splay, warping, or cracking?

Yes. We specialize in identifying whether a defect is caused by the material (contamination/moisture), the process (temperature/pressure), or the tooling (gate location/cooling). We provide actionable recommendations to get your production line back on track.

12. Can you simulate part performance using Finite Element Analysis (FEA)?

Absolutely. We specialize in Non-Linear FEA, which is essential for plastics because they do not behave like metals. We account for time-dependent behavior (creep), temperature sensitivity, and fiber orientation to predict exactly how your part will perform before you cut steel for a mold.

13. Do you help with Moldflow analysis and injection molding optimization?

Yes. We use advanced simulation tools to predict potential manufacturing defects such as gas traps, weld line weaknesses, and excessive shrinkage. Our goal is to optimize the process to reduce cycle times while maintaining part integrity.

Training & Education

14. Does The Madison Group offer customized on-site training for engineering teams?

Absolutely. In addition to our public courses, we can bring our expertise to your facility. We tailor the curriculum to your team’s specific needs—whether that is focused on injection molding, plastic part design, or failure prevention.

15. Are your technical seminars available in a virtual or webinar format?

Yes. We can offer Live Virtual Training, providing an interactive environment where your team can engage with our experts in real-time without the need for travel. Additionally, we host several complimentary webinars annually, covering emerging trends and foundational topics in polymer science to keep your engineering team informed and competitive.

16. How do I register for your upcoming material selection course?

Registration for our professional development courses, including the September 29 – October 1 session in Schaumburg, IL, can be completed directly through our “Events” page. These courses are designed for engineers looking to deepen their understanding of plastic behavior and failure prevention.

Logistics

17. How do I request a quote for a specific project?

The fastest way to get started is to email us at [email protected] or submit a request for information through our contact webpage. For failure analysis projects, providing a brief description of the issue will help our engineers provide an accurate scope of work more quickly.

18. Where should I ship samples for testing, and how should they be labeled?

Please ship all samples to our headquarters at:

The Madison Group
2615 Research Park Drive
Madison, WI 53711

To ensure a smooth intake process, please include a packing slip with your full contact information. We recommend padding parts securely to prevent “shipping-induced” damage that could interfere with our analysis.

Important Note for Contamination Analysis: If you are submitting parts to identify surface contamination, please do not ship them in plastic bags or wrap, as this can lead to cross-contamination. We prefer these samples to be wrapped in pre-cleaned aluminum foil to preserve the integrity of the surface.