Sunny...I wish it were so easy as to say exactly what goes wrong. I've ask the question time after time...why do they develop all the way to about 18 days, then die without pipping? Or they pip the aircell and then die before zipping and hatching?
I will say this. EXCEPT FOR SILKIES...keeping the humidity on the lower side during incubation (around 30-35%) and then increasing to around 65% day 19 - 21 and running the temp just a bit higher (around 100.3) I had better luck when using a styrofoam bator. I know some folks have great hatches in the styrofoam bators but I could NOT hatch worth a crap in them and sold mine. I had better hatches in my homemade incubator with temp swings than I did in the styro bator.
Since I bought my Rcom Suro King, I've had great hatches....and I don't know why. Perhaps it's the ventilation...they need enough fresh air being drawn in. It is terribly discouraging, I know. I was just about to give up completely and just purchase chicks, but the Rcom was on sale and I decided to take one more stab at it.
Shipped eggs are certainly harder to hatch, but generally it's related to the eggs developing at all.