DeWalt Flap Disc Recall Lawsuit | 2025 Latest Updates

Flap Disc Lawsuit Overview

This lawsuit follows the July 3, 2025 recall by the U.S. Consumer Product Safety Commission (CPSC) of approximately 17,680 DEWALT Elite Series 4.5″ 40G T27 high-density flap discs—models DWA8280HRT and DWA8280RT—sold from September 2024 to May 2025.

The ceramic cloth abrasive flaps can detach during use, potentially causing cuts, lacerations, eye injuries, and related safety hazards.

At least three incidents resulting in cuts and scrapes have been reported, underscoring the dangerous design defect and the manufacturer’s possible negligence in quality control and user warnings.

Latest Flap Disc Lawsuit Updates

• July 3, 2025 – CPSC initiates the recall after confirming that ceramic flaps can detach under normal use, posing serious physical injury risks [1.].
• July 4, 2025 – DEWALT’s official safety notice is published, instructing users to stop use immediately and contact the company for a refund [2.].

Flap Disc Lawsuit Statistics

• Units recalled: Approximately 17,680 flap discs.
• Incidents reported: Three confirmed detachment-related injuries involving cuts or abrasions.
• Price range: Sold for $7–$10 each through industrial suppliers (Grainger, Fastenal, Airgas) and Amazon from September 2024 to May 2025.

Design Defect & Hazard Analysis

The primary defect involves failure of the bonding mechanism that secures ceramic cloth flaps to the disc backing. This detachment under normal operational speeds creates a significant laceration hazard—DEWALT’s failure to address this in testing or provide adequate user warnings supports strict liability, negligence, and breach of warranty claims.

Injuries & Side Effects

Injuries from the defective flap discs may include:

• Lacerations and abrasions: From high-velocity debris and sharp fragments.
• Eye trauma: Potential foreign objects entering the eye if eye protection is not worn.
• Psychological distress: Emotional trauma resulting from sudden on-tool failures.

Do You Qualify?

You may qualify if you:

• Used a recalled DEWALT Elite Series 4.5″ 40G T27 flap disc (DWA8280HRT or DWA8280RT) between September 2024–May 2025.
• Suffered cuts, scrapes, eye injury, or related harm from a disc detachment.
• Can provide proof of purchase and evidence of the disc and injury (photos, witness or medical records).
• Complied with recall instructions or ceased use after the July 2025 recall.

Evidence Required

• Product evidence: Photograph or actual disc with model/date code showing DWA8280HRT or DWA8280RT.
• Proof of purchase: Invoices, receipts, order records from supplier or Amazon.
• Medical documentation: Photos of injuries, ER or doctor reports, treatment costs.
• Recall notice proof: Screenshot or email showing DEWALT recall instructions.
• Incident details: Statements or evidence from witnesses, workplace safety logs, etc.

Damages You Can Recover

• Medical expenses: ER visits, sutures, prescription medication, specialist follow-ups.
• Pain & suffering: Emotional and physical distress from the injury.
• Lost wages: Income lost due to recovery downtime.
• Punitive damages: Possible if DEWALT ignored known safety risks.

Recall Instructions & Consumer Action

• Recall date: July 3, 2025.
• Units: DEWALT Elite Series 4.5″ 40G T27 High Density Flap Discs, models DWA8280HRT and DWA8280RT, date codes 2024‑36 to 2024‑48.
• Hazard: Ceramic cloth flaps can detach under normal use, causing laceration and projectile.
• Remedy: Stop using the discs immediately. Visit DEWALT’s recall portal to upload a photo and certify disposal; receive a full refund.

Statute of Limitations & Urgency

Legal claims for product defects and bodily injuries must be filed within **two to five years** from the date of incident or recall, depending on your state. Promptly documenting injuries, preserving any remaining disc, and retaining medical records or witness accounts is crucial to support your claim.

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Frequently Asked Questions

• Do I need to keep the damaged disc? Yes—having it preserved or documented helps link your injury to the specific product.
• Can I sue if I only had minor scrapes? Yes—even less severe injuries may qualify for compensation under product liability law.
• Is DEWALT responsible even if I wore protection? Yes—because defective discs should not pose risks, regardless of user behavior.
• Do I need a lawyer? Yes—these cases involve technical evidence about tool safety and manufacturing standards requiring professional legal guidance.
• What if I received a refund? A refund only covers the product cost—it doesn’t waive your right to seek compensation for injuries or losses.

References

1. https://www.cpsc.gov/Recalls/2025/DEWALT-Recalls-Grinder-Flap-Discs-Due-to-Laceration-and-Injury-Hazards
2. https://www.dewalt.com/support/safety-notices-and-recalls/flap-disc-recall
3. https://www.yahoo.com/news/dewalt-recalls-thousands-grinder-flap-150000460.html