Key answer
Incomplete filling, bubbles, brittleness, tack, deformation and active loss usually require a root-cause review across formula and process.
Incomplete tips or trapped air
Review viscosity, deaeration, mold wetting, filling energy and hold time.
Brittle or deformed arrays
Review polymer balance, solids, plasticization, residual moisture, drying uniformity and storage.
Unexpected active loss
Review identity, pH, interactions, oxygen, light, temperature, adsorption and analytical recovery.
Editorial boundary: General cosmetic development information only. Verify the actual formula, product, method and market requirements.