SUMMARYThis paper presents an advanced failure surface propagation concept based on the marching cubes algorithm initially proposed in the field of computer graphics and applies it to the embedded finite element method. When modeling three‐dimensional (3D) solids at failure, the propagation of the failure surface representing a crack or shear band should not exhibit a strong sensitivity to the details of the finite element discretization. This results in the need for a propagation of the discrete failure zone through the individual finite elements, which is possible for finite elements with embedded strong discontinuities. Whereas for two‐dimensional calculations the failure zone propagation location is easily predicted by the maximal principal stress direction, more advanced strategies are needed to achieve a smooth failure surface in 3D simulations. An example for such method is the global tracking algorithm, which predicts the crack path by a scalar level set function computed on the basis of the solution of a simplified heat conduction like problem. Its prediction may though lead to various scenarios on how the failure surface may propagate through the individual finite elements. In particular, for a hexahedral eight‐node finite element, 256 such cases exist. To capture all those possibilities, the marching cubes algorithm is combined with the global tracking algorithm and the finite elements with embedded strong discontinuities in this work. In addition, because many of the possible cases result in non‐planar failure surfaces within a single finite element and because the local quantities used to describe the kinematics of the embedded strong discontinuities are physically meaningful in a strict sense only for planar failure surfaces, a remedy for such scenarios is proposed. Various 3D failure propagation simulations outline the performance of the proposed concept. Copyright © 2013 John Wiley & Sons, Ltd.