After locating the initial fracture site and pinpointing the suspect area where the failure initiated, consider modifying the part design to minimize the negative effects of the suspect area. For example, if the failure occurs at a sharp wall thickness transition, consider making the transition more gradual to better distribute stress.

The removal of these suspect areas is often a minimal process. Increasing a radius is usually a minor tooling cost; however, it can make drastic changes to the part performance.