The structural breakdown was caused by the failure of rubber O-rings in the right solid rocket booster. Unusually cold temperatures on the morning of the launch caused the O-rings to stiffen and fail to seal, allowing hot gases to escape and ignite the external fuel tank. Engineers at a NASA contractor warned about this risk before launch, but their concerns were overruled.
The disaster grounded the shuttle fleet for nearly three years, exposing serious organizational failures within NASA. The subsequent investigation found that the agency had normalized known risks and communication between engineers and leadership had broken down, prompting significant changes to NASA's safety oversight and decision-making culture.