Expert Witness Used ChatGPT to Defend 3M in Deadly Explosion Lawsuit—His Prompts Were Subpoenaed

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An expert witness hired by 3M used ChatGPT to write his report defending the company in a lawsuit over a Houston explosion that killed three people. Discovery revealed 350 pages of AI prompts, including requests to show 3M was "0% at fault." The case exposes how AI in legal proceedings creates new risks when prompts become discoverable evidence.

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Expert Witness Used ChatGPT to Create Report Defending 3M

Josh Autenrieth of Knighthawk Engineering relied on ChatGPT to generate significant portions of his expert witness report in a 3M lawsuit stemming from a deadly explosion at Watson Grinding in Houston. The January 2020 blast killed three people and destroyed roughly 200 homes. Court records show Autenrieth explicitly instructed the AI to "create an exceptional expert witness report defending the standard of care at 3M" and to "show how 3M is 0% at fault for the explosion at Watson Grinding."

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3M paid Knighthawk Engineering roughly $90,000 for the analysis, with Autenrieth billing at $475 per hour.

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Discovery Process Exposes AI-Generated Report and Prompts

During legal discovery, Will Moye, one of the plaintiffs' attorneys, identified a five-page "Citation Overlay" document that appeared AI-generated. Recognizing the ChatGPT formatting, Moye demanded all prompts Autenrieth used from 3M's legal team. The deposition paused for three hours while 350 pages of ChatGPT conversations were gathered.

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These documents included public links to Autenrieth's full conversations with the AI platform. The subpoenaed transcripts revealed that Autenrieth told ChatGPT he was "being retained as a professional expert witness by 3M in defense of them in their lawsuits and other legal proceedings behind the January 2020 explosion."

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ChatGPT Generated 30-Page Report Claiming Zero Negligence

Autenrieth uploaded hundreds of court records and asked ChatGPT to read them, then defend 3M while "illustrating the lack of [Process and Safety Management] and safety by Watson Grinding" and showing "how 3M is 0% at fault."

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The AI-generated report initially included the line "From a technical and standard-of-care standpoint, 3M is 0% responsible for the January 24, 2020 explosion."

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When Autenrieth later asked ChatGPT to "review this as the opposing council," the AI identified that "'0% responsible' is an easy target" for lawyers to attack, calling such phrases problematic because they "paint you as an advocate rather than an expert."

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Expert Witness Asked AI to Identify Equipment Central to Case

The prompts revealed Autenrieth uploaded an image of a gas detector and asked ChatGPT "what am I looking at?" and "what are model names of industrial gas detectors."

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According to Moye, that gas detector is "the subject of the whole case."

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This raises questions about Autenrieth's actual expertise, despite his purported twenty years of experience in gas detection.

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Ethical Implications and AI Misuse in Legal Proceedings

"This expert relied on AI not as an assistive device, but exclusively relied on ChatGPT to form his opinions and write his report," Moye stated. "He acknowledged [at trial] the prompts he put in were biased toward 3M to help 3M win the case... it's really egregious."

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The case demonstrates how AI in legal proceedings has evolved beyond AI-generated legal briefings and hallucinated cases to include expert witness testimonies. The explosion was caused by a "degraded and poorly crimped rubber welding hose" that leaked flammable gas, according to the U.S. Chemical Safety and Hazard Investigation Board.

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Plaintiffs alleged 3M failed to properly service the facility's gas detection system.

Discoverability of AI Prompts Creates New Legal Landscape

The case establishes that ChatGPT prompts can be discoverable during legal proceedings, creating significant implications for how AI is used in courtrooms. "Every lawyer needs to make sure their own experts aren't generating work product in a way that's insincere, and then knowing you can subpoena the prompts," Moye explained. "I've got lawyers all over the place saying, 1) 'Holy shit, man. How did you get the prompts?,' and 2) 'How many cases do I have where this is happening to us?'"

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The discoverability of AI prompts means legal teams must now consider whether their experts' use of AI tools could expose biased or unprofessional work processes. With hundreds of millions of dollars in total liability at stake across multiple lawsuits related to the Watson Grinding explosion, this case signals that AI-generated expert witness reports may face increased scrutiny and that the specific prompts used can become embarrassing evidence against the parties who commissioned them.

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