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The encyclopedia · Product & Design · Product decision · 1960

The Xerox 914 copier caught fire so often that Xerox shipped fire extinguishers with it

The first plain-paper copier was a revolution — and a fire hazard. Paper jams in the heat-fusing unit ignited, and Xerox had to redesign the mechanism.

Xerox · 1960

What happened

The Xerox 914, introduced in 1959 by the Haloid Company (which renamed itself Xerox in 1961), was the first commercially successful plain-paper copier. It was a sensation — offices that had relied on messy carbon paper and chemical processes could now make clean copies on ordinary paper. Demand was enormous.

But the 914 had a dangerous flaw. Its xerographic process used a heated fusing unit to bond toner to paper, and paper jams in the fuser could ignite. The machine caught fire often enough that Xerox shipped a small fire extinguisher with each unit and trained service technicians to respond to fire calls. The problem was serious enough to threaten the product's reputation.

Xerox engineers redesigned the fusing mechanism and added safety interlocks to reduce the fire risk. The 914 went on to become one of the most successful office products in history, generating billions in revenue and making Xerox a dominant force in office equipment. But the early fire problems were a stark lesson in shipping a product before the engineering was fully mature.

Why it happened

  • The xerographic fusing process required high heat, and paper jams in the fuser created an ignition source.
  • The product was rushed to market to meet enormous demand before the safety engineering was fully mature.
  • Early units lacked adequate safety interlocks to prevent operation when the fuser was in an unsafe state.
  • The fire risk was known but accepted as a trade-off for being first to market with plain-paper copying.
What it costfire damage; service calls; reputational riskembarrassing

The lesson

Being first to market does not excuse shipping known safety defects. A product that catches fire loses trust faster than a delayed product loses market share.

Aftermath

Xerox redesigned the 914's fusing mechanism and added safety interlocks. The product went on to generate billions in revenue and made Xerox the dominant office-equipment company of the 1960s and 70s. The early fire problems became a footnote in the product's history, but a lasting lesson in the cost of shipping before the engineering is ready.

Sources

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