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When a Set Screw Plays a Part in a $327 Million Failure

Dec 30, 2025

Most people are familiar with the infamous failure of the Mars Climate Orbiter, often citing the metric-to-imperial unit conversion error as the sole culprit. While that indeed played a critical role, a lesser-known contributing factor was something far smaller, yet equally devastating: loosened socket set screws in the guidance modules.

Imagine a journey spanning 140 million miles. Over that immense distance and extended timeframe, improper torquing and the absence of a crucial locking compound allowed these tiny set screws to gradually back out. This seemingly minor shift had major consequences, subtly altering the alignment of critical sensors within the orbiter's navigation system.

Those minute misalignments, compounded by the already flawed navigation data, meant that NASA's course corrections were fatally inaccurate. The result? The Mars Climate Orbiter entered the Martian atmosphere at a dangerously low altitude and was tragically destroyed, leading to a loss of $327 million and invaluable scientific opportunity.

🔧 The Lesson Learned: Small Components, Monumental Impact

This incident serves as a stark reminder: even the smallest components, like set screws, can have monumental implications. When they're responsible for maintaining precision alignment in a sophisticated navigation system traversing vast interstellar distances, their integrity is non-negotiable. "Good enough" simply isn't an option.

For applications in aerospace, defense, medical devices, or any field demanding absolute precision manufacturing, the quality and reliability of every single component are paramount. Specifications matter. Quality control matters. And ultimately, mission success depends on it.

At SESCO Precision, we understand the critical role that precision fasteners play in high-stakes environments. We specialize in manufacturing and supplying socket set screws with locking elements that meet the most stringent specifications, ensuring the reliability and performance your projects demand.

📩 Don't let a small component lead to a big problem.

If you're seeking a reliable partner for high-quality socket set screws and other precision fasteners, let's connect. Your mission's success is our priority.