Each year, millions of Americans suffer injuries from consumer products, and thousands of these incidents prove fatal, according to data from the U.S. Consumer Product Safety Commission (CPSC). While most products are designed with safety in mind, a growing number of recalls across a broad range of everyday household items raises questions about manufacturing standards and oversight. Over the past five years, product recalls in the U.S. have surged by nearly 40%.
This rise in recalls comes at a time of major transformation in the manufacturing industry. Many companies have begun reshoring production to the U.S., driven in large part by higher tariffs, as well as federal and state-level tax incentives aimed at boosting domestic manufacturing. These policy shifts are designed to rebuild critical supply chains and reduce reliance on foreign suppliers, but they’ve also brought new challenges—some of which may not be felt immediately, due to the long-term nature of reshoring.
According to ETQ’s 2025 Pulse of Quality in Manufacturing Survey, 67% of manufacturers report that workforce shortages or skills gaps are affecting operations, and 85% of those say these issues have had a direct impact on product or service quality. Meanwhile, regulatory oversight has become a political flashpoint. In a recent and politically contentious development, President Donald Trump sought to fire several members of the CPSC—a move challenged in court but ultimately permitted by a recent Supreme Court ruling.
With safety issues on the rise and the future of the CPSC in question, quality management software company ETQ conducted a review of the largest product recalls reported by the agency so far in 2025. The analysis not only identifies the scale and scope of major recalls, but also looks at how the frequency of recalls have changed over time, the most common causes of consumer product recalls, and ultimately what these incidents mean for both consumers and manufacturers.
Number of Consumer Product Recalls by Year
The total number of product recalls increased by 40% between 2020 and 2024
Source: ETQ analysis of U.S. Consumer Product Safety Commission data
Product recalls in the United States have risen sharply in recent years. According to CPSC data, the number of product recalls increased by nearly 40% between 2020 and 2024, rising from 238 to 333. This growth suggests that despite manufacturers’ efforts to improve safety and quality control, systemic vulnerabilities in design, production, or oversight persist across industries.
That trend is echoed in industry sentiment. According to ETQ’s recent survey, 75% of manufacturers reported experiencing at least one product recall in the past five years—a slight increase from 73% in 2024. In just the first seven months of 2025, the CPSC has issued 312 recalls, already approaching last year’s total. If this pace holds, 2025 is on track to mark a new high in product quality failures. Notably, in the first seven months of 2025, recalls affected more than 24 million consumer units.
The Cost of Product Recalls to Manufacturers
Product recalls typically cost firms $10M–$50M in refunds, repairs, or replacements
Source: ETQ analysis of U.S. Consumer Product Safety Commission and ETQ’s 2025 Pulse of Quality in Manufacturing data
When a product is recalled, manufacturers must provide a remedy to affected consumers—most commonly in the form of refunds, repairs, or replacements. According to government data, refunds are the most frequently offered remedy, accounting for 46.9% of all recall responses. Repairs follow at 30.7%, and product replacements at 19.6%. In rare cases, the remedy involves product disposal (1.6%) or updated usage instructions (0.6%). It is extremely rare for no remedy to be available, occurring in just 0.5% of recalls issued by the agency.
These remedies carry significant financial consequences for firms. ETQ data shows that nearly half of manufacturers who experienced a recall in recent years reported remediation costs between $10 million and $50 million. An additional 13% faced costs exceeding $50 million, while just 6% kept total losses under $5 million. These figures include direct expenses such as consumer reimbursements, scrap, rework and warranty costs, as well as broader impacts from reputational damage, supply chain disruptions, and legal exposure.
Top Causes of Product Recalls
The potential for fires, burns, or explosions are the most common reasons for consumer product recalls
Source: ETQ analysis of U.S. Consumer Product Safety Commission data
Among consumer products, thermal hazards—specifically fires, burns, and heat-related explosions—remain the most common causes of recalls in the U.S. Fire hazards are cited in 21.5% of recalls, followed by burns (17.4%) and heat-related explosions (15.7%). These risks are especially prevalent in products powered by lithium-ion batteries, such as laptops, power banks, and smart devices, as well as in kitchen appliances like stoves, air fryers, and pressure cookers. These categories often combine electrical or thermal components with frequent handling, raising the likelihood of malfunction and injury.
Other common causes include falls (13.6%), crashes (8.5%), and poisoning risks (8.2%). Structural or mechanical failures in household products—such as the recent Cosco 2-Step Kitchen Stepper recall—can lead to serious fall injuries. John Deere compact tractors were recently recalled over brake issues that created crash hazards, while several children’s products have been pulled from the market for violating federal safety standards related to chemical exposure.
Additional hazards that frequently lead to recalls include malfunctioning safety equipment (7.0%), such as smoke alarms that fail to operate properly; impact hazards (6.4%) caused by components that eject or detach during use; and choking (6.1%) and ingestion (6.0%) risks, particularly in children’s toys and accessories. These categories reflect ongoing safety issues in both everyday household items and children’s products, where even small defects can have big consequences.
Top 10 Product Recalls of 2025
The recall of nearly 4 million BowFlex adjustable dumbbells was the largest so far in 2025
Source: ETQ analysis of U.S. Consumer Product Safety Commission data
With the number of recalls in just the first seven months of 2025 already approaching last year’s total, the scale of impact is also growing. So far this year, 29 major product recalls have involved 100,000 units or more, including 10 recalls that each affected 500,000 units or more. These recalls have spanned a wide range of categories, from fitness equipment and outdoor products to household appliances and consumer electronics.
1. BowFlex Adjustable Dumbbells (3.84 million units)
Johnson Health Tech Trading recalled approximately 3.8 million BowFlex adjustable dumbbells—models 552 and 1090—after reports of weight plates detaching during use, creating a serious impact hazard. Altogether, the company logged 337 such incidents, including 111 injuries such as concussions, abrasions, broken toes, and contusions. Consumers are being offered refunds or replacements depending on the seller, and the units were sold through major retailers including Best Buy, Amazon, and DICK’S Sporting Goods.
2. HydroTech Expandable Burst-Proof Hoses (3.60 million units)
Winston Products recalled 3.6 million 5/8-inch expandable garden hoses after receiving at least 222 reports of the hoses bursting. These incidents resulted in 29 injuries, including bone bruises, sprains, and at least five cases of temporary hearing loss due to the sudden, loud burst. Sold at Walmart, Home Depot, and other retailers, the hoses were marketed as “burst-proof” but could fail under pressure.
3. SharkNinja Foodi Pressure Cookers (1.85 million units)
SharkNinja recalled nearly 1.85 million Foodi OP300 Series pressure cookers due to a malfunction that allowed the lid to open during use, causing hot contents to escape. At least 106 burn injuries have been reported, over 50 of which involved second- or third-degree burns. The company has faced 26 lawsuits as a result. Consumers are being provided replacement lids and advised to avoid using the pressure-cooking function until the fix is in place.
4. Midea U and U+ Window Air Conditioners (1.70 million units)
Midea recalled about 1.7 million U and U+ Window Air Conditioners, sold under brands such as Midea, Comfort Aire, Danby, Frigidaire, Insignia, Keystone, LBG Products, Mr. Cool, Perfect Aire, and Sea Breeze, due to a risk of mold exposure. Pooled water can fail to drain properly, leading to mold growth and potential respiratory issues or allergic reactions. The company has received 152 mold reports, including 17 cases of related health symptoms. Consumers can request a free repair or refund.
5. Igloo 90 Qt. Flip & Tow Rolling Coolers (1.19 million units)
Igloo expanded its previous recall of 90 Qt. Flip & Tow Rolling Coolers to nearly 1.2 million units due to a tow handle defect that can pinch fingers, posing amputation and crushing hazards. Since February 2025, there have been 78 injury reports, including 26 fingertip amputations, fractures, or lacerations. Consumers should stop using the cooler immediately and contact Igloo for a free replacement handle.
Other notable recalls so far in 2025 include:
- Anker PowerCore 10000 power banks (1.16 million units) due to fire hazards, with 19 incidents of fires or explosions.
- Pura 4 Fragrance Diffusers (851,400 units) as a result of magnets that can detach and pose an ingestion hazard to children.
- Ozark Trail 64 oz Steel Water Bottles (850,000 units), resulting from a flaw that led to lids forcefully ejecting and injuring consumers.
- Frigidaire Minifridges (634,000 units), whose internal electrical components can short circuit, potentially causing fires and burns.
- LG Slide-In and Freestanding Electric Ranges (500,000 units), linked to more than 28 fires resulting from unintentional activation of its front-mounted knobs.
Together, these 10 recalls alone affected more than 16 million consumer units, highlighting persistent challenges in product design, manufacturing oversight, and safety assurance. For a complete list of the largest product recalls issued so far in 2025, including details on the products, associated hazards, manufacturing origin, and the remedies provided, see The Largest Consumer Product Recalls of 2025 on ETQ.
Methodology
Photo Credit: Pressmaster / Shutterstock
The data used in this report comes from two primary sources: the U.S. Consumer Product Safety Commission (CPSC) Recalls Database and the 2025 Pulse of Quality in Manufacturing Survey from ETQ. The CPSC tracks recalls for thousands of consumer products under its jurisdiction, including household appliances, electronics, furniture, children’s products, and recreational equipment. It does not cover automobiles, pharmaceuticals, or food products, which fall under the authority of other federal agencies.
The analysis of individual product recalls focuses on the seven-month period between January 1, 2025 and July 31, 2025. The ranking of the largest recalls is based on the number of units affected as reported by CPSC, as detailed cost data for individual recalls is not publicly available. Only the largest 25 recalls are included in the full results.
For complete results, see The Largest Consumer Product Recalls of 2025 on ETQ.
