The problems encountered with sintered metal parts in printer magnet units and the analytical methods used to determine the failure mechanism and type of contamination present are discussed. These methods involved the use of Fourier transform IR spectroscopy, scanning electron microscopy, energy-dispersive X-ray spectroscopy and wet chemical techniques. The mechanical device employed for laboratory simulation of the failure mechanism is also discussed. This investigation indicates that a cutting fluid used to machine parts was the primary source of contamination. Residual cutting fluid in the presence of a sliding mating surface resulted in the formation of a viscous waxy build-up on the mating surfaces, which adversely influenced the motion of the print hammer.