The alien Russ pulled broke at 900lbs. Were you able to generate 4KN with your bounce test? Chris from BD said he was able to generate 1000lbs doing some serious bouncing with several inches of free-fall; I don't think I was able to generate that much force in my bounce tests.
The aliens that failed in the field all failed with body weight or small falls... maybe a bounce test would have helped, maybe not. The loop swage failure certainly would have been detected.
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"Be ot or bot ne ot, tath is the nestquoi." Thamle, by Malliwi Rapesheake