Engineering Sciences

Polymers & Coatings

Polymers & Coatings Capabilities

Secretariat’s Engineering Sciences team supports clients across the full lifecycle of coatings and polymer products, combining advanced analytical science with real‑world industry experience to solve high‑stakes technical, regulatory, and commercial challenges. Our work is often used to support litigation or assist companies with product failures and managing material and regulatory risk — helping them understand what failed, why it failed, how to respond, and how to prevent future risk. 

Industries We Support

Secretariat’s polymers and coatings expertise spans a broad range of materials‑driven industries, including:

  • Coatings (protective, decorative, functional)
  • Adhesives & sealants
  • Consumer products
  • Energy storage and battery systems
  • Construction materials
  • Packaging & plastics.

Why Choose Secretariat for Polymer & Coatings Expertise

Our distinguished, highly experienced experts work at the intersection of materials science, risk assessment, and failure analysis. With decades of multidisciplinary experience and an extensive understanding of how formulation, structure, and processing conditions influence material behavior in real-world environments, our specialists are regularly trusted by global clients to advise on product failures, regulatory scrutiny, and high-profile disputes.

Our team combines deep materials science expertise with advanced analytical capabilities, spanning fracture mechanics, multi-scale failure analysis, and imaging techniques such as CT and SEM to deliver clear, defensible answers when outcomes matter most.

We support clients across:

  • Failure analysis & root cause investigations
  • Supply chain & manufacturing challenges
  • Regulatory compliance & product risk assessment
  • Litigation & expert support
  • Product development & performance optimization

Across each engagement, Secretariat delivers expert insights that are technically sound, data-driven, and able to withstand rigorous examination by regulators, opposing experts, and legal counsel. 

Areas of Expertise

Advanced Materials Characterization

We leverage a comprehensive suite of state‑of‑the‑art analytical tools to evaluate coatings and polymer systems, identify failure mechanisms, assess compliance, and support defensible conclusions. We apply a wide range of techniques to connect detailed material characterization to real-world performance, including: 

  • Microscopy: SEM / EDS, optical microscopy 
  • Spectroscopy: FTIR, NMR 
  • Thermal analysis: DSC, TGA 
  • Mechanical testing: tensile testing, rheology 
  • Imaging: X‑ray, CT 
  • Other techniques: GCMS 
Failure Analysis & Root Cause Investigation

Our experts investigate complex product and field failures to determine what happened and why, and the implications for performance, liability, and risk. We provide independent, evidence‑based conclusions suitable for technical, regulatory, and legal contexts. Typical issues include: 

  • Coating delamination, blistering, cracking, and adhesion loss 
  • Polymer degradation (thermal, oxidative, UV, environmental exposure) 
  • Contamination and material defects 
  • Battery and polymer interface failures 
  • Unexpected or premature field performance issues 

We examine critical factors such as design, material selection, manufacturing processes, environmental conditions, and mechanical stress to establish clear, defensible root-cause analyses. 

Supply Chain & Manufacturing Support

Supply disruption and quality failures create operational and legal risk. Secretariat’s experts help clients diagnose issues, quantify impact, and mitigate these challenges through: 

  • Raw material equivalence and substitution assessments 
  • Batch‑to‑batch variability investigations 
  • Manufacturing and process troubleshooting 
  • Quality failures in production and fielded products 

Our findings help clients understand how changes in materials or processes may have caused or contributed to these challenges, providing a clear basis for remediation and risk mitigation. 

Regulatory Compliance & Product Risk Assessment

We support proactive and reactive risk management for regulated and safety‑critical products. Our work includes: 

  • Hazard identification and risk assessments 
  • Product safety and exposure evaluations 
  • Technical support for regulatory inquiries and enforcement actions 
  • Failure risk, liability, and exposure assessments 

Our analyses are structured to withstand scrutiny from regulators, insurers, and opposing experts. 

Litigation & Expert Support

We provide independent, defensible technical expertise throughout the dispute lifecycle. Our experts are trusted by counsel, insurers, and corporate legal teams to deliver clarity in technically complex cases. Our services include: 

  • Independent technical investigations 
  • Expert report development 
  • Evidence review, critique, and rebuttal 
  • Deposition, mediation, and trial support 
Product Development & Performance Optimization

In addition to dispute and risk work, we support clients and organizations in improving product performance and reliability across coatings and polymer systems. We advise on:  

  • Formulation development support (adhesives, coatings, functional polymers) 
  • Additive selection (stabilizers, flame retardants, fillers) 
  • Performance enhancement (mechanical, thermal, durability) 
  • Scale‑up and manufacturability support 

Our work helps clients translate material science insights into practical improvements in product design, performance, and long-term sustainability

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