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K-Fail: Polymer Failure Prediction and Remaining Useful Life Software

Every material has a failure date. Yours is unknown. K-Fail connects your degradation data and operating conditions to an exact remaining useful life, so you replace on data, not guesses.

What Is the Damage Index™?

A unified 0–100% metric that measures cumulative damage across all active damage modes, including their interactions.

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37%

Life Remaining

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ElastoSure Products Powering K-FAIL

FORMULATION OPTIMIZATION

polymer formulation optimization software​​

• Test 10× fewer compounds

• Compress 18-month cycles to days

• Accelerated aging test replacement​

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The Real Cost Isn't Aging. It's Uncertainty.

Conventional testing is slow and expensive. K-Fail predicts remaining life before failure occurs.

01
Over Replacement
Replacing materials too early wastes time, money, and valuable service life.
02
Under Replacment
Replacing materials too late increases the risk of failures and costly downtime.
03
Field Failures
Unexpected failures interrupt operations and reduce product reliability.
04
Qualification Delays
Long testing cycles delay approvals and slow product development.

Accelerating the Digital Transformation of Industry with Simulation

Every industy faces unique, constantly evolving challenges. ElastoSure delivers the expertise, capabilities and tools to transform the design and production processes of industries.

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Oil & Gas

Model seal and elastomer degradation under heat, pressure, H2S, chemicals, and long-duration downhole exposure.

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Defense & Aerospace

Support mission-life prediction for polymer components under extreme environments, storage, radiation, thermal cycling, and mechanical fatigue.

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Rubber & Elastomers

Predict when seals, O-rings, gaskets, and elastomer components approach leakage, stiffness loss, cracking, or compression-set thresholds.

Decision-Ready Lifetime Predictions

Predict shelf life, remaining useful life, failure thresholds, and uncertainty, all in one simulation.

MODELS
Predicts how materials change throughout their service life.
▪  Material Aging
▪  Fatigue Behavior
▪  Failure Thresholds
ELIMINATES
Removes uncertainty before costly failures occur.
▪  Guesswork
▪  Unexpected Failures
▪  Qualification Delays
DELIVERS
Provides engineering insights for faster, confident decisions.
▪  Remaining Useful Life (RUL)
▪  Failure Probability
▪  Risk-Based Decisions

How K-Fail Works

From raw material data to decision-ready lifetime predictions in four simple steps.

INPUT DATA
Collect the material, environmental, and loading conditions that define real-world performance before prediction begins.
▪ Material properties
Mechanical loading
Environmental conditions
Test & qualification data
AGING MODEL
Physics-based simulation combines material science with AI to model how degradation evolves throughout the service life.
Physics
+
AI
Lifetime Simulation
FAILURE THRESHOLD
Identify the point where performance no longer satisfies safety, reliability, or certification requirements.
▪ Failure probability
Critical degradation point
Safety margin
REMAINING USEFUL LIFE
Convert imulation results into actionable maintenance and replacement decisions with confidence.
Prediction
Risk
Service Window
8.7 Years
Low
2.1–3.4 
Years

Real-World Proof Behind the Polymer Aging & Durability Simulation Software

Prediction Accuracy

95% 

For long-term durability prediction

Experimental Tests

80,000+

Used for training and validation

vs. 6 Months

35 Days 

Replacing long-weathering tests

Faster Analysis

5–10× 

Compared to traditional FE models

Frequently Asked Questions

Learn how K-Fail predicts material lifetime, supports engineering decisions, and integrates into your existing workflow.

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K-Fail

Assessment of Remaining Useful Life in Polymeric Components

Reliability analysis of polymeric components is based on identifying remaining useful life (RUL) and exposure to environmental and mechanical stressors. K-Fail computes RUL from radiation and thermal oxidation during service, as well as strength loss caused by one-time extreme events.

Brochures

Case Study

Download our technical case studies.

01

Case Study 

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Works with Your Existing Engineering Stack

INTEGRATIONS

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Compatible

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Developer access

Compatible

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Coming Q3 2026

Start your 30-day free trial.

No credit card. No commitment. Replace your next aging test with a digital twin.

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