dts-2026Presentation/test_modes_slides.md

Safety Test Modes Reference

One Slide Per Test Mode

Comprehensive Guide to Automotive and Sports Safety Testing

Prepared for: DTS (Diversified Technical Systems)
Purpose: Technical reference for safety testing instrumentation
Total Slides: 32 (27 test modes + 5 section dividers)

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SECTION 1: NHTSA / FMVSS REGULATORY TESTS

Tests in This Section:

1. FMVSS 208 - Full Frontal Impact
2. FMVSS 214 - Side Impact (MDB)
3. FMVSS 214 - Side Pole Impact
4. FMVSS 216 - Roof Crush Resistance
5. FMVSS 301 - Fuel System Integrity
6. FMVSS 208 - Out-of-Position (OOP) Testing
7. FMVSS 213 - Child Restraint Systems
8. FMVSS 201 - Interior Impact (Free Motion Headform)

These are mandatory compliance tests required for vehicles sold in the United States.

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FMVSS 208 - Full Frontal Impact

NHTSA | Introduced: 1968 (crash test 1984) | Full Vehicle Crash Test

Purpose

Evaluates occupant protection in head-on collisions. The most fundamental crash test - simulates a vehicle striking a fixed barrier (like a concrete wall) at highway speed. Forms the basis of the NCAP 5-star rating system.

Test Setup

Parameter	Value
Speed	35 mph (56 km/h)
Barrier	Rigid concrete wall
Overlap	100% full width
Vehicle	Production vehicle
Orientation	Perpendicular to barrier

Dummy & Instrumentation

Item	Specification
Driver ATD	Hybrid III 50th percentile male
Passenger ATD	Hybrid III 5th percentile female
Total Channels	~94 (47 per dummy)
Key Sensors	Head triaxial accel, chest accel, chest deflection, femur load cells, neck load cells

Injury Criteria & Limits

Metric	Limit	Body Region	CFC
HIC₁₅	≤ 700	Head	1000
HIC₃₆	≤ 1000	Head	1000
Peak Head Accel (3ms)	≤ 80g	Head	1000
Chest Accel (3ms)	≤ 60g	Thorax	180
Chest Deflection	≤ 63 mm (50th) / 52 mm (5th)	Thorax	600
Femur Load	≤ 10 kN	Lower Extremity	600
Nij (all modes)	≤ 1.0	Neck	600
Neck Tension	≤ 4,170 N (50th)	Neck	600
Neck Compression	≤ 4,000 N	Neck	600

Image: assets/crash_test_dummies_subaru.jpg

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FMVSS 214 - Side Impact (Moving Deformable Barrier)

NHTSA | Introduced: 1990 (dynamic) | Full Vehicle Crash Test

Purpose

Evaluates occupant protection when struck broadside by another vehicle. Side impacts are particularly dangerous because there is minimal crush space between the door and the occupant - only inches separate life and death.

Test Setup

Parameter	Value
MDB Speed	33.5 mph (54 km/h)
MDB Mass	3,015 lb (1,368 kg)
MDB Angle	27° crabbed (not perpendicular)
Impact Point	Driver side, centered on H-point
Target Vehicle	Stationary
Barrier Face	Deformable aluminum honeycomb

Dummy & Instrumentation

Item	Specification
Driver ATD	ES-2re (Euro SID - rib extension)
Rear ATD	SID-IIs (5th percentile female)
Total Channels	~80
Key Sensors	Head accel, rib deflections (3 levels), pelvis accel, abdominal force

Injury Criteria & Limits

Metric	Limit	Body Region	CFC
HIC₃₆	≤ 1000	Head	1000
Lower Spine Accel	≤ 82g (ES-2re)	Pelvis	1000
Rib Deflection	≤ 44 mm (any rib)	Thorax	600
Abdominal Force	≤ 2.5 kN	Abdomen	600
Pubic Force	≤ 6 kN	Pelvis	600
V*C (Viscous)	≤ 1.0 m/s	Thorax	-

Image: assets/iihs_side_barrier.jpg

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FMVSS 214 - Side Pole Impact

NHTSA | Introduced: 2007 | Full Vehicle Crash Test

Purpose

Simulates a vehicle sliding sideways into a narrow fixed object like a tree or utility pole. These crashes concentrate force on a small area, causing severe intrusion. Added after recognizing that MDB tests alone didn't capture this failure mode.

Test Setup

Parameter	Value
Speed	20 mph (32 km/h)
Pole Diameter	254 mm (10 inches)
Impact Angle	75° (oblique, not perpendicular)
Impact Location	Driver's head position
Vehicle Movement	Vehicle propelled into stationary pole

Dummy & Instrumentation

Item	Specification
Driver ATD	ES-2re or WorldSID
Total Channels	~40
Key Sensors	Head accel, thorax ribs, pelvis accel

Injury Criteria & Limits

Metric	Limit	Body Region	CFC
HIC₃₆	≤ 1000	Head	1000
Rib Deflection	≤ 44 mm	Thorax	600
Lower Spine Accel	≤ 82g	Pelvis	1000
Abdominal Force	≤ 2.5 kN	Abdomen	600

Note: Side curtain airbags became critical for passing this test.

Image: assets/iihs_side_2021.jpg

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FMVSS 216 - Roof Crush Resistance

NHTSA | Introduced: 1973 (1.5×), Upgraded 2009 (3×) | Static Test

Purpose

Ensures the roof structure can support the vehicle's weight during a rollover, preventing catastrophic collapse onto occupants' heads. The 2009 upgrade doubled the strength requirement after research showed the original standard was inadequate.

Test Setup

Parameter	Value
Test Type	Static (no crash)
Force Application	Angled steel plate
Plate Angle	25° from horizontal
Force Required	≥ 3× vehicle unloaded weight
Test Duration	Force maintained for 5 seconds
Tested Area	Both driver and passenger sides

Instrumentation

Item	Specification
ATD	None (static test)
Measurements	Applied force, roof displacement
Channels	~4-6
Key Sensors	Load cells under plate, displacement transducers

Performance Criteria

Metric	Requirement
Strength-to-Weight Ratio	≥ 3.0
Maximum Displacement	≤ 127 mm (5 inches) before reaching 3×
Both Sides	Must pass independently

Historical Note: The original 1.5× standard was criticized as too weak. After the Ford Explorer/Firestone rollover crisis, the 2009 upgrade to 3× was implemented.

Image: assets/roof_strength_test.jpg

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FMVSS 301 - Fuel System Integrity

NHTSA | Introduced: 1968, Revised 1977 (post-Pinto) | Full Vehicle Crash Test

Purpose

Prevents fuel leakage after crashes to reduce fire risk. The infamous Ford Pinto case (fuel tank rupturing in rear impacts) led to strengthened requirements in 1977.

Test Setup - Rear Impact

Parameter	Value
Speed	50 mph (80 km/h) - rear moving barrier
Barrier Mass	4,000 lb (1,814 kg)
Configuration	MDB strikes rear of stationary vehicle

Test Setup - Side Impact

Parameter	Value
Speed	20 mph (32 km/h)
Configuration	MDB strikes side

Test Setup - Rollover

Parameter	Value
Procedure	Vehicle rotated 360°
Duration	Hold at 90°, 180°, 270° positions

Instrumentation

Item	Specification
ATD	None (fuel leakage test)
Measurements	Fuel leakage volume
Duration	5 minutes post-crash for static leak

Performance Criteria

Metric	Limit
Fuel Leakage (impact)	≤ 28g during impact
Fuel Leakage (static)	≤ 142g/min post-crash
Rollover Leakage	≤ 142g/min at each position

Historical Note: "It's cheaper to let them burn" memo from Ford became infamous. Estimated $11 fix vs. $200M in settlements.

Image: assets/cadaver_crash_test.jpg (for general crash imagery)

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FMVSS 208 - Out-of-Position (OOP) Testing

NHTSA | Introduced: 2000 (Advanced Airbag Rule) | Static Deployment Test

Purpose

Ensures airbags don't injure or kill occupants who are too close to the airbag at deployment. After 175+ deaths from early aggressive airbags (mostly children and small adults), this test was added.

Test Configurations

Position	Description
Position 1	Chin on airbag module (close proximity)
Position 2	Chest on airbag module
Position 3	Abdomen on airbag module
Position 4	Child seat in front passenger position

Dummy & Instrumentation

Item	Specification
ATDs Used	Hybrid III 5th female, 6-year-old, 3-year-old, 12-month CRABI
Total Channels	~30 per test
Key Sensors	Head/neck loads, chest deflection

Injury Criteria & Limits (5th Female)

Metric	Limit	Body Region
HIC₁₅	≤ 700	Head
Nij	≤ 1.0	Neck
Neck Tension	≤ 2,620 N	Neck
Chest Deflection	≤ 52 mm	Thorax

Key Requirements

• Suppression: Airbag must suppress for rear-facing child seats
• Depowering: Lower inflation force than pre-1998 airbags
• Multi-stage: Variable deployment force based on crash severity

Image: assets/crabi_infant_dummy.jpg

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FMVSS 213 - Child Restraint Systems

NHTSA | Introduced: 1971, Revised Multiple Times | Sled Test

Purpose

Ensures child car seats protect children in crashes. Tests the child restraint system itself, not the vehicle.

Test Setup

Parameter	Value
Test Type	Sled test (simulated crash)
Delta-V	30 mph (48 km/h)
Peak G	23-26g
Pulse Duration	~80 ms
Seat Bench	Standardized test bench

Dummy Types by Size

Dummy	Represents	Weight
CRABI 12-month	12-month infant	22 lb (10 kg)
Hybrid III 3-year-old	Toddler	33 lb (15 kg)
Hybrid III 6-year-old	Child	51 lb (23 kg)
Hybrid III 10-year-old	Older child	79 lb (36 kg)

Instrumentation

Item	Specification
Total Channels	~15-20 per dummy
Key Sensors	Head accel, chest accel, head excursion

Injury Criteria & Limits

Metric	Limit	Notes
HIC₃₆	≤ 1000	All dummies
Head Excursion	≤ 720 mm	Distance traveled forward
Knee Excursion	≤ 915 mm	Distance traveled forward
Chest Accel (3ms)	≤ 60g	All dummies

Image: assets/child_dummy_booster.jpg

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FMVSS 201 - Interior Impact (Free Motion Headform)

NHTSA | Introduced: 1968, Upgraded 1998 (Upper Interior) | Component Test

Purpose

Ensures interior surfaces (A-pillar, B-pillar, roof rail, header) don't cause severe head injury when occupants strike them during crashes. Led to padded pillars and roof-mounted airbags.

Test Setup

Parameter	Value
Test Type	Component (not full vehicle crash)
Impactor	Free Motion Headform (FMH)
FMH Mass	4.5 kg (10 lb)
Impact Speed	15 mph (24 km/h)
Target Areas	A-pillar, B-pillar, C-pillar (if present), roof rail, header

Instrumentation

Item	Specification
FMH Sensors	Triaxial accelerometer
Total Channels	3 (x, y, z acceleration)
Sample Rate	≥ 8,000 Hz
Filter	CFC 1000

Injury Criteria

Metric	Limit	Location
HIC(d)	≤ 1000	All target points

Note: HIC(d) is a modified HIC calculation for the FMH test.

Test Point Grid

• Multiple impact points mapped across each pillar/header
• Each point tested separately
• All points must pass

Image: assets/iihs_dummy_sensors.jpg

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SECTION 2: IIHS CONSUMER INFORMATION TESTS

Tests in This Section:

1. IIHS Moderate Overlap Frontal
2. IIHS Small Overlap Frontal (Driver + Passenger)
3. IIHS Side Impact (2021 Updated)
4. IIHS Roof Strength
5. IIHS Head Restraint / Whiplash (Discontinued 2020)
6. IIHS Front Crash Prevention - Vehicle to Vehicle
7. IIHS Headlights
8. IIHS Front Crash Prevention - Pedestrian

IIHS tests are voluntary consumer information ratings (Good/Acceptable/Marginal/Poor), not regulatory requirements.

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IIHS Moderate Overlap Frontal

IIHS | Introduced: 1995 | Full Vehicle Crash Test

Purpose

Simulates a head-on crash where only part of each vehicle's front structure is engaged - the most common type of serious frontal crash. More demanding than the FMVSS 208 full-frontal test because it bypasses part of the crush structure.

Test Setup

Parameter	Value
Speed	40 mph (64 km/h)
Overlap	40% of vehicle width
Barrier	Deformable aluminum honeycomb
Barrier Height	650 mm
Barrier Width	1,000 mm
Barrier Depth	Progressive crush stiffness

Dummy & Instrumentation

Item	Specification
Driver ATD	Hybrid III 50th percentile male
Total Channels	~47
Key Sensors	Head accel, neck loads, chest accel/deflection, femur loads, tibia loads

Injury Criteria Assessment

Body Region	Good	Acceptable	Marginal	Poor
Head/Neck	Low risk	Elevated risk	High risk	Very high risk
Chest	Low risk	Elevated risk	High risk	Very high risk
Hip/Thigh	Low risk	Elevated risk	High risk	Very high risk
Lower Leg/Foot	Low risk	Elevated risk	High risk	Very high risk

Structural Assessment

• Intrusion measurements at multiple points
• Steering column displacement
• Door opening post-crash
• Fuel system integrity

Image: assets/iihs_frontal_crash_test.jpg

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IIHS Small Overlap Frontal

IIHS | Introduced: 2012 (Driver), 2017 (Passenger) | Full Vehicle Crash Test

Purpose

Addresses crashes where only the corner of the vehicle hits an object (tree, pole, corner of another vehicle). Many vehicles that aced moderate overlap tests failed this test initially, including premium brands like BMW, Mercedes, and Audi.

Test Setup

Parameter	Value
Speed	40 mph (64 km/h)
Overlap	25% of vehicle width
Barrier	RIGID (not deformable)
Barrier Edge	Rounded
Tests	Driver side AND Passenger side (separate tests)

Dummy & Instrumentation

Item	Specification
ATD	Hybrid III 50th percentile male
Total Channels	~47
Key Sensors	Head, neck, chest, femur, tibia, foot

Key Evaluation Areas

Assessment	What It Measures
Structure	Intrusion into occupant compartment
Dummy Kinematics	Did occupant stay in protective zone?
Injury Measures	Risk to head/neck, chest, hip/thigh, leg/foot
Restraints	Did airbags deploy correctly?

Historical Impact

• 2012 launch: Only 3 of 13 midsize cars earned "Good"
• BMW 5-series, Mercedes C-Class, Audi A4 all rated "Marginal" or "Poor"
• Led to fundamental structural redesigns across the industry

Image: assets/small_overlap_test.jpg or assets/iihs_small_overlap_overhead.jpg

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IIHS Side Impact (Updated 2021)

IIHS | Introduced: 2003, Updated 2021 | Full Vehicle Crash Test

Purpose

Simulates a T-bone crash with a larger, heavier striking vehicle (typical modern SUV). The 2021 update increased barrier weight and speed to reflect real-world vehicle size increases.

Test Setup (2021 Protocol)

Parameter	Original (2003)	Updated (2021)
Barrier Speed	31 mph (50 km/h)	37 mph (60 km/h)
Barrier Mass	3,300 lb (1,500 kg)	4,200 lb (1,905 kg)
Ground Clearance	300 mm	Higher (SUV-like)
Face Height	Standard	Taller
Impact Location	Driver side	Driver side

Dummy & Instrumentation

Item	Specification
Front ATD	SID-IIs (5th percentile female)
Rear ATD	SID-IIs (5th percentile female)
Total Channels	~60
Key Sensors	Head accel, torso ribs, pelvis loads

Injury Assessment Areas

Body Region	Sensors
Head/Neck	Acceleration, HIC
Torso	Rib deflection (3 levels)
Pelvis	Acceleration, pubic force

Rating Criteria

• Driver and rear passenger injuries combined
• Structural intrusion measurements
• Head protection (did head contact hard surfaces?)

Image: assets/iihs_side_2021.jpg

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IIHS Roof Strength

IIHS | Introduced: 2009 | Static Test

Purpose

Evaluates roof strength for rollover protection. IIHS standards exceed federal requirements - "Good" requires 4× vehicle weight (vs. FMVSS 216's 3×).

Test Setup

Parameter	Value
Test Type	Static (quasi-static loading)
Plate Angle	25° (same as FMVSS 216)
Loading Rate	No faster than 5 mm/second
Crush Limit	127 mm (5 inches)

Rating Thresholds

Rating	Strength-to-Weight Ratio
Good	≥ 4.0
Acceptable	3.25 - 3.99
Marginal	2.50 - 3.24
Poor	< 2.50

Note on Testing

• Both driver and passenger sides tested
• Weaker side determines overall rating
• Some vehicles exceed 6× or 7× vehicle weight

Discontinued: IIHS stopped rating roof strength after 2016 because nearly all vehicles earn Good.

Image: assets/roof_strength_test.jpg

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IIHS Head Restraint / Whiplash

IIHS | Introduced: 2004 (dynamic) | Sled Test | DISCONTINUED 2020

Purpose

Evaluated protection against whiplash in rear-end crashes. Whiplash causes more injury claims than any other crash type, though injuries are typically less severe.

Test Setup

Parameter	Value
Test Type	Sled test (seat mounted on sled)
Delta-V	10 mph (16 km/h)
Peak Acceleration	~10g
Pulse Shape	Simulates rear-end crash

Dummy

Item	Specification
ATD	BioRID II (Biofidelic Rear Impact Dummy)
Special Features	24-vertebrae articulated spine
Total Channels	~35
Key Sensors	Head accel, neck forces/moments, spine motion

Evaluation Criteria

Metric	What It Measured
Time to Head Restraint Contact	How quickly head reached restraint
Torso Acceleration	Peak torso acceleration
Neck Shear	Maximum neck shear force
Neck Tension	Maximum neck tension

Why Discontinued

• Nearly all seats now earn "Good"
• IIHS developing more demanding rear-impact test

Image: assets/hybrid_iii_family.jpg (for dummy reference)

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IIHS Front Crash Prevention - Vehicle to Vehicle

IIHS | Introduced: 2013 | Track Test

Purpose

Evaluates automatic emergency braking (AEB) and forward collision warning (FCW) systems. These systems detect imminent collisions and warn the driver or apply brakes automatically.

Test Scenarios (Current Protocol)

Target	Configuration
Passenger Vehicle	Stationary target, centered and offset
Motorcycle	Stationary target, centered and offset
Semi-trailer	Stationary dry van (FCW only)

Test Speeds

Speed	Test Type
31 mph (50 km/h)	Low speed
37 mph (60 km/h)	Medium speed
43 mph (69 km/h)	High speed

Instrumentation

Item	Measurement
GPS	Precise vehicle position
Speed	Instantaneous velocity
Deceleration	Braking force applied
FCW Timing	Time before projected collision

Rating Criteria

Component	Weight
Speed Reduction (AEB)	2/3 of score
Warning Timing (FCW)	1/3 of score
Requirement	Warning ≥ 2.1 seconds before impact

Targets Used

• GST (Global Vehicle Target) - passenger car surrogate
• PTM (Powered Two-wheeler Target) - motorcycle surrogate
• Actual dry van trailer - semi-truck scenario

Image: assets/iihs_fcp_car_target.png

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IIHS Headlights

IIHS | Introduced: 2016 | Track Evaluation

Purpose

Evaluates headlight illumination distance and glare. Good headlights provide crucial reaction time for avoiding obstacles at night. Testing revealed huge variation between vehicles - some "luxury" vehicles had poor headlights.

Test Setup

Parameter	Value
Test Track	Straight and curved sections
Curves	500-foot and 800-foot radius
Measurements	Light intensity at road surface
Conditions	Nighttime, dry pavement

Evaluation Criteria

Metric	Description
Illumination Distance	How far light reaches (straight)
Curve Performance	Illumination on curves
High Beam Assist	Automatic switching
Glare	Light directed at oncoming drivers

Rating Factors

Factor	Impact
Low Beam - Straight	Primary factor
Low Beam - Curves	Critical for safety
High Beam	Additional credit
Excessive Glare	Deductions

Key Findings

• Wide variation even within same model (trim levels)
• Halogen vs. LED vs. HID differences
• Curve-adaptive headlights significantly better

Image: assets/iihs_crash_hall.jpg (IIHS facility)

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IIHS Front Crash Prevention - Pedestrian

IIHS | Introduced: 2019 | Track Test

Purpose

Evaluates whether AEB systems can detect and brake for pedestrians. Pedestrian fatalities have increased as SUV sales grew - detecting pedestrians is harder than detecting vehicles.

Test Scenarios

Scenario	Description
Adult - Perpendicular	Adult dummy crossing road
Adult - Parallel	Adult walking along road edge
Child - Perpendicular	Child dummy darting into road

Test Speeds

Speed	Scenario
25 mph (40 km/h)	Adult perpendicular
37 mph (60 km/h)	Adult perpendicular
25 mph (40 km/h)	Child perpendicular

Targets

Target	Description
Adult Dummy	50th percentile male body form
Child Dummy	6-year-old size body form
Movement	Propelled across or along roadway

Rating Criteria

Rating	Requirements
Superior	Avoid or substantially reduce impact in all scenarios
Advanced	Significant speed reduction
Basic	Warning only, limited braking

Test Conditions

• Daytime testing (night testing added 2024 by Euro NCAP)
• Clear weather
• Defined target paths

Image: assets/euroncap_headform.png (pedestrian protection concept)

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SECTION 3: NCAP CONSUMER RATING TESTS

Tests in This Section:

1. NHTSA NCAP 5-Star Frontal
2. NHTSA NCAP 5-Star Side
3. Euro NCAP MPDB (Mobile Progressive Deformable Barrier)

NCAP programs provide star ratings for consumer comparison. They use similar tests to regulatory requirements but publish comparative results.

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NHTSA NCAP 5-Star Frontal

NHTSA | Introduced: 1979 | Full Vehicle Crash Test

Purpose

Provides consumers with comparative frontal crash safety ratings. Same test as FMVSS 208 but results published as 1-5 star ratings based on injury probability.

Test Setup

Parameter	Value
Speed	35 mph (56 km/h)
Barrier	Rigid wall
Overlap	100% full frontal
Configuration	Same as FMVSS 208

Dummy & Instrumentation

Item	Specification
Driver ATD	Hybrid III 50th male
Passenger ATD	Hybrid III 5th female
Total Channels	~94

Star Rating System

Stars	Combined Injury Probability
5 stars	≤ 10%
4 stars	11% - 20%
3 stars	21% - 35%
2 stars	36% - 45%
1 star	≥ 46%

Injury Probability Calculations

Based on:

• HIC₁₅
• Chest acceleration
• Chest deflection
• Femur loads

Note: Driver and passenger rated separately, then combined.

Image: assets/crash_test_dummies_subaru.jpg

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NHTSA NCAP 5-Star Side

NHTSA | Introduced: 1997 (MDB), 2011 (Pole added) | Full Vehicle Crash Test

Purpose

Provides consumers with comparative side crash safety ratings. Combines MDB and pole tests for overall side rating.

Test Setup - MDB

Parameter	Value
Speed	38.5 mph (62 km/h)
Barrier Mass	3,015 lb (1,368 kg)
Angle	27° crabbed
Target	Driver side

Test Setup - Pole

Parameter	Value
Speed	20 mph (32 km/h)
Pole	254 mm diameter
Angle	75° oblique
Target	Driver side

Dummy & Instrumentation

Position	ATD
Driver	ES-2re (MDB) / WorldSID (Pole)
Rear	SID-IIs 5th female

Star Rating

Test	Weight in Overall
MDB	Combined with pole
Pole	Combined with MDB
Overall	Single side rating

Image: assets/iihs_side_barrier.jpg

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Euro NCAP MPDB (Mobile Progressive Deformable Barrier)

Euro NCAP | Introduced: 2020 | Full Vehicle Crash Test

Purpose

Simulates a head-on crash between two vehicles of similar size. Unlike fixed-barrier tests, this measures the test vehicle's "aggressivity" - how much damage it inflicts on the other car.

Test Setup

Parameter	Value
Test Vehicle Speed	50 km/h (31 mph)
Trolley Speed	50 km/h (31 mph)
Overlap	50%
Trolley Mass	1,400 kg (3,086 lb)
Barrier	Progressive deformable face

Dummy & Instrumentation

Position	ATD
Driver	THOR-50M (advanced frontal dummy)
Rear	Q6 and Q10 child dummies

THOR-50M Advantages

Feature	Benefit
Multi-point chest	More accurate rib loading
Instrumented abdomen	Detects abdominal injury
Flexible spine	Better kinematics
Deformable face	Facial injury assessment

Unique Assessment: Compatibility

Measure	Purpose
Barrier Deformation	How much damage test vehicle caused
Deformation Pattern	Was damage concentrated or distributed?
Compatibility Penalty	Aggressive vehicles penalized

Rating Contribution

• Occupant protection scores
• Compatibility modifier (can reduce score)
• Child occupant scores

Image: assets/thor_dummy.jpg

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SECTION 4: PEDESTRIAN PROTECTION

Tests in This Section:

1. Euro NCAP Pedestrian - Legform Impact
2. Euro NCAP Pedestrian - Headform Impact
3. Euro NCAP AEB Pedestrian/Cyclist

Pedestrians account for ~17% of global road fatalities. These tests drive vehicle design changes like raised hoods, energy-absorbing structures, and active safety systems.

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Euro NCAP Pedestrian - Legform Impact

Euro NCAP | Introduced: 1997, Updated Multiple Times | Component Test

Purpose

Evaluates bumper design for pedestrian leg injuries. When a vehicle strikes a pedestrian, the bumper typically contacts the leg first, causing knee and lower leg injuries.

Test Setup

Parameter	Value
Impactor	Flexible lower legform
Impact Speed	40 km/h (25 mph)
Target Area	Front bumper
Test Points	Multiple locations across bumper width

Impactor Specifications

Component	Specification
Upper Leg Mass	8.6 kg
Lower Leg Mass	4.8 kg
Total Mass	13.4 kg
Knee Joint	Deformable, instrumented

Instrumentation

Measurement	Sensor
Knee Bending Angle	Rotary potentiometer
Knee Shear	Displacement transducer
Tibia Acceleration	Accelerometer
Tibia Bending	Strain gauges

Injury Criteria

Metric	Higher Performance	Lower Performance
Knee Bending	≤ 15° (green)	≥ 21° (red)
Knee Shear	≤ 3.5 mm (green)	≥ 6.0 mm (red)
Tibia Acceleration	≤ 150g (green)	≥ 200g (red)

Image: assets/euroncap_headform.png

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Euro NCAP Pedestrian - Headform Impact

Euro NCAP | Introduced: 1997, Updated 2023 | Component Test

Purpose

Evaluates hood and windshield design for pedestrian head injuries. The hood surface and windshield base are where pedestrians' heads typically strike.

Test Setup

Parameter	Value
Impact Speed	40 km/h (25 mph)
Impactor	Adult headform (4.5 kg) / Child headform (3.5 kg)
Target Area	Hood surface, windshield base
Test Points	Grid of impact locations

Headform Specifications

Type	Mass	Diameter
Adult	4.5 kg	165 mm
Child	3.5 kg	130 mm

Instrumentation

Channel	Sensor
Head X-acceleration	Accelerometer
Head Y-acceleration	Accelerometer
Head Z-acceleration	Accelerometer
Resultant	Calculated

Injury Criterion

Metric	Good (Green)	Adequate (Yellow)	Poor (Red)
HIC₁₅	≤ 650	650 - 1000	≥ 1700

Hood Design Implications

• Raised hoods (space for deformation)
• Energy-absorbing hinges
• Pop-up hood systems (deploy on impact)
• Soft hood inner structures

Image: assets/euroncap_headform.png

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Euro NCAP AEB Pedestrian/Cyclist

Euro NCAP | Introduced: 2016 (Pedestrian), 2018 (Cyclist), 2024 (Night) | Track Test

Purpose

Evaluates active safety systems that detect pedestrians and cyclists and automatically brake to avoid or mitigate collisions.

Pedestrian Test Scenarios

Scenario	Code	Description
Adult Crossing	CPFA	50th percentile adult, far-side crossing
Adult Crossing	CPNA	50th percentile adult, near-side crossing
Adult Longitudinal	CPLA	Adult walking along road edge
Child Running	CPNC	Child darting from behind obstruction

Cyclist Test Scenarios

Scenario	Code	Description
Cyclist Crossing	CBFA	Cyclist crossing from far side
Cyclist Longitudinal	CBLA	Cyclist in same direction
Cyclist Door Opening	-	Vehicle preventing door strike

Test Speeds

Speed	Scenarios
20 km/h	Low speed urban
40 km/h	Medium speed
60 km/h	Higher speed

Rating Criteria

Performance	Score Impact
Full Avoidance	Maximum points
Speed Reduction	Partial points
Warning Only	Minimal points
No Response	Zero points

2024 Update: Night Testing

• Pedestrian detection in darkness
• Tests with low ambient light
• Evaluates sensor capability (camera vs. radar vs. LiDAR)

Image: assets/euroncap_cyclist_headform.png

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SECTION 5: SPORTS / HELMET TESTING

Tests in This Section:

1. NOCSAE Football Helmet - Drop Test
2. NOCSAE Football Helmet - Linear Impactor
3. NOCSAE Lacrosse Helmet
4. Ice Hockey Helmet (ASTM/HECC/CSA)
5. FMVSS 218 - Motorcycle Helmet

Sports helmet testing prevents catastrophic brain and skull injuries. NOCSAE standards have reduced football fatalities by over 90% since 1973.

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NOCSAE Football Helmet - Drop Test

NOCSAE | Introduced: 1973 | Drop Test

Purpose

Ensures football helmets attenuate head impact energy to prevent skull fracture and severe brain injury. The founding test that created modern helmet safety standards after multiple football deaths in the 1960s-70s.

Test Setup

Parameter	Value
Drop Height	60 inches (152 cm) standard
Additional Heights	36, 48, 72 inches
Headform	Humanoid (rigid)
Anvil Types	Flat, hemispherical, cylindrical, edge
Temperature	Ambient, hot (100°F), cold (14°F)

Instrumentation

Channel	Specification
Headform Accelerometer	Triaxial
Sample Rate	≥ 10,000 Hz
Filter	CFC 1000

Injury Criterion: Severity Index (SI)

SI = \int_0^T a(t)^{2.5} \, dt

Condition	SI Limit
New Helmet	SI < 1200
Recertified	SI < 1200
Single Impact	Peak < 1200

Test Sequence

Drop	Location	Height
1-4	Front, side, rear, top	60"
5+	Random locations	Varies
Conditioning	Multiple impacts	Per protocol

Historical Impact

• Pre-1973: 32 football fatalities per year (average)
• Post-standard: Reduced to ~3 per year (90%+ reduction)

Image: assets/hybrid_iii_family.jpg (headform concept)

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NOCSAE Football Helmet - Linear Impactor (Pneumatic Ram)

NOCSAE | Added: 2016 | Ram Impact Test

Purpose

Evaluates helmet performance under oblique (glancing) impacts that cause rotational acceleration - linked to concussions. Supplements drop tests to address rotational brain injury.

Test Setup

Parameter	Value
Impactor Type	Pneumatic ram
Ram Mass	~13 kg
Impact Speed	5.5-9.3 m/s (varies by test)
Impact Locations	Multiple angles
Headform	Hybrid III head/neck

Instrumentation

Channel	Measurement
Linear Acceleration	3-axis accelerometer
Rotational Acceleration	Angular rate sensors
Rotational Velocity	Calculated

Key Measurements

Metric	Significance
Peak Linear Accel	Brain injury risk
Peak Rotational Accel	Concussion risk
Peak Rotational Velocity	Strain on brain tissue

Impact Configurations

Location	Angle
Front	Centric and offset
Side	Centric and offset
Rear	Centric and offset
Oblique	Various angles

Rating Systems (NFL/NFLPA)

• Combined with drop test data
• Laboratory Accuracy Score (LAS)
• Publicly ranked for player selection

Image: assets/atd_family.png

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NOCSAE Lacrosse Helmet

NOCSAE | Standard: ND041 | Drop Test + Projectile Impact

Purpose

Protects against both collision impacts (player-to-player, ground) and ball impacts (lacrosse ball at high speed). Combines impact attenuation with projectile protection.

Drop Test Setup

Parameter	Value
Drop Heights	60, 48, 36 inches
Headform	Humanoid
Anvil Types	Flat, hemispherical
Faceguard	Tested attached to helmet

Ball Impact Test

Parameter	Value
Projectile	Lacrosse ball (NOCSAE spec)
Ball Speed	45 mph (20 m/s)
Impact Locations	Multiple on faceguard and shell

Instrumentation

Channel	Specification
Head Acceleration	Triaxial
Sample Rate	≥ 8,000 Hz
Filter	CFC 1000

Injury Criteria

Test	Limit
Drop SI	< 1200
Ball Impact SI	< 1200
Faceguard Penetration	None allowed

Men's vs Women's

• Men's: Full helmet with faceguard
• Women's: Historically only goggles (changing)
• Different standards apply

Image: assets/atd_family.png

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Ice Hockey Helmet (ASTM/HECC/CSA)

HECC/CSA/ASTM | Multiple Standards | Drop Test + Puck Impact

Purpose

Protects against falls (hitting ice/boards), collisions (player-to-player), and puck impacts (frozen puck at 100+ mph). Must also allow for facemask/cage integration.

Standards Landscape

Standard	Organization	Region
CSA Z262.1	CSA Group	Canada
ASTM F1045	ASTM	USA
HECC	Hockey Equipment Certification Council	North America
CE EN 1077	European Committee	Europe

Drop Test Setup

Parameter	Value
Drop Heights	1.5 m, 2.0 m
Headform	ISO/CSA specified
Anvils	Flat, hemispherical, edge
Conditioning	Hot, cold, wet

Puck Impact Test

Parameter	Value
Puck Mass	170 g (official)
Impact Speed	25-40 m/s (varies by standard)
Target	Shell and faceguard

Instrumentation

Channel	Specification
Linear Acceleration	Triaxial
Peak g	Primary criterion

Pass/Fail Criteria

Test	Criterion
Drop (flat anvil)	Peak < 275g (CSA)
Drop (hemispherical)	Peak < 275g
Puck Impact	No shell fracture, peak g limits
Facemask	No puck penetration

Image: assets/atd_family.png

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FMVSS 218 - Motorcycle Helmet

NHTSA | Introduced: 1968 | Drop Test + Penetration Test

Purpose

Establishes minimum safety requirements for motorcycle helmets sold in the United States. Known as "DOT certification" - every street-legal helmet must pass.

Drop Test Setup

Parameter	Value
Drop Heights	Varies by impact location
Anvils	Flat and hemispherical
Headform	ISO headforms (multiple sizes)
Conditioning	Ambient, hot, cold, wet

Test Locations

Location	Drop Height
Crown	1.83 m (flat), 1.38 m (hemi)
Front	1.83 m (flat), 1.38 m (hemi)
Side	1.83 m (flat), 1.38 m (hemi)
Rear	1.83 m (flat), 1.38 m (hemi)

Penetration Test

Parameter	Value
Striker	3 kg pointed steel cone
Drop Height	3 m
Criterion	No contact with headform

Instrumentation

Channel	Specification
Peak Acceleration	< 400g
Duration	Measured

Pass/Fail Criteria

Test	Limit
Peak Acceleration	≤ 400g
Penetration	No headform contact
Retention	Strap holds

Comparison to Other Standards

Standard	Peak g Limit	Notes
DOT (FMVSS 218)	400g	Minimum federal standard
Snell	275g (M2020)	More stringent, voluntary
ECE 22.06	Complex	European, includes rotational

Image: assets/john_stapp_portrait.jpg (pioneer who survived 46g)

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APPENDIX: QUICK REFERENCE

CFC Filter Classes

CFC	-3dB Frequency	Primary Use
CFC 1000	1000 Hz	Head acceleration
CFC 600	600 Hz	Chest, pelvis
CFC 180	180 Hz	Structural
CFC 60	60 Hz	Gross motion

Common Injury Criteria Summary

Criterion	Formula/Description	Typical Limit
HIC₁₅	Head Injury Criterion (15 ms)	≤ 700
HIC₃₆	Head Injury Criterion (36 ms)	≤ 1000
Nij	Neck Combined Load Index	≤ 1.0
CTI	Combined Thoracic Index	≤ 1.0
SI	Severity Index (helmets)	< 1200
V*C	Viscous Criterion	≤ 1.0 m/s

ATD Quick Reference

Dummy	Primary Use	Channels
Hybrid III 50th Male	Frontal	~47
Hybrid III 5th Female	Frontal (small)	~47
ES-2re	Side (FMVSS)	~40
SID-IIs	Side (IIHS)	~35
WorldSID	Side (harmonized)	~50
BioRID II	Rear (whiplash)	~35
THOR-50M	Frontal (advanced)	~150
Q-Series	Children	Varies

Key Standards Documents

Document	Organization	Topic
SAE J211-1	SAE	Electronic instrumentation
SAE J211-2	SAE	Photographic instrumentation
ISO 6487	ISO	Measurement techniques (=J211)
CFR 49 Part 571	NHTSA	FMVSS regulations
NOCSAE ND001	NOCSAE	Headgear test equipment

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Document Version: 1.0
Created: February 2026
Purpose: DTS Safety Testing Presentation Reference
Total Slides: 32 (27 test modes + 5 section dividers)