Just taking an intuitive stab here as I've never heard the term "explosive fracture" before... But, because you mentioned flutter - I imagine it's a fancy term for fatigue failure when there's a high cycle/second count... Am I on the right track?
As far as making things robust.... The easiest way to determine if there's something bad coming your way (at least, a very telling symptom).... Listen for noise. Noise is vibration, and vibration can lead to fatigue or other failure (fasteners coming out etc.). Interestingly, on my drive across alligator alley today, I hit some large bugs that blasted their way through my grille block
It was made using a wig makers mold technique
But ya, things flying off is a pretty good reason to avoid sharp edges, points, etc. If it's going to fly off, make sure it's got a soft landing