Editor's Note: This story originally appeared on ETQ.
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 raise 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.
Here are the top product recalls of 2025.
1. BowFlex Adjustable Dumbbells (3.84 million units)
- Product details: Johnson Health Tech Trading recalls BowFlex 552, 52.5 LB Adjustable Dumbbells and BowFlex 1090, 90 LB Adjustable Dumbbells due to impact hazard.
- Approximate units recalled: 3,844,200
- Date: 6/5/2025
- Remedy: Refund, Replace
- Manufactured in: China
- Hazard description: The weight plates can dislodge from the handle during use, posing an impact hazard.
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)
- Product details: Winston Products recalls HydroTech 5/8-inch Expandable Burst-Proof Hoses due to risk of impact hazard and temporarily impaired hearing.
- Approximate units recalled: 3,600,000
- Date: 7/24/2025
- Remedy: Refund
- Manufactured in: Cambodia, China, Vietnam
- Hazard description: The recalled hoses can burst, posing an impact hazard and a risk of temporarily impaired hearing.
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)
- Product details: SharkNinja recalls Foodi OP300 Series Multi-Function Pressure Cookers due to burn hazard.
- Approximate units recalled: 1,846,400
- Date: 5/1/2025
- Remedy: Repair
- Manufactured in: China
- Hazard description: The pressure-cooking lid can be opened during use, causing hot contents to escape, posing a risk of burn injuries to consumers.
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)
- Product details: Midea recalls U and U+ Window Air Conditioners due to risk of mold exposure.
- Approximate units recalled: 1,700,000
- Date: 6/5/2025
- Remedy: Refund, Repair
- Manufactured in: China, Thailand
- Hazard description: Pooled water in the air conditioners can fail to drain quickly enough, which can lead to mold growth.
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)
- Product details: Igloo recalls 90 Qt. Flip & Tow Rolling Coolers due to fingertip amputation and crushing hazards.
- Approximate units recalled: 1,190,000
- Date: 5/8/2025
- Remedy: Replace
- Manufactured in: United States
- Hazard description: The tow handle can pinch consumers’ fingertips against the cooler, posing fingertip amputation and crushing hazards.
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
- 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 front-mounted knobs.
Together, these recalls alone affected more than 16 million consumer units, highlighting persistent challenges in product design, manufacturing oversight, and safety assurance.
Methodology
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.
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