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In this paper, the premature failure of the integral droppers in high speed railway catenary in China was investigated. Series of microscopic characterization and analysis were conducted to identify the root causes of the unexpected failure. By numerically simulating the existing crimping behavior, distribution of the contact stress in the dropper was obtained. It was found that there was stress concentration at the dropper sliced end, which became the primary reason for the permanent distortion and damage on the droppers, and consequently resulted in the untimely final fracture with bending fretting fatigue acting. Through the failure analysis and numerical simulation, a scheme of the improvements in measuring the existing crimping was brought up. Meanwhile, a plan was also put forward to change the current crimping model and reduce the depth of indentation of clamp tube. Static tensile tests and bending fretting fatigue tests were carried out to evaluate the optional plans, which would help extend the service life of integral dropper in practice. [ABSTRACT FROM AUTHOR]