Crash-Test Reinvented: Inside IIHS’s New Protocol

Why XSensor’s high-speed impact system is now critical for vehicle design. As the Insurance Institute for Highway Safety (IIHS) tightens its crash‑test protocols, vehicle manufacturers need to act. IIHS’s new Moderate Overlap Frontal Crashworthiness Evaluation 2.0 requires belt‑position data via high‑speed pressure mapping—data captured using XSensor’s High‑Speed Impact System on anthropomorphic test devices (ATDs).

With China and Europe NCAP expected to follow suit, the era of pressure‑mapping-informed safety testing is here.

Vehicle impact testing – what has changed?

IIHS’s revised protocol moves beyond traditional accelerometers, mandating direct measurement of belt position and pressure during impact. These metrics are critical for evaluating real-world occupant protection and are now an official part of vehicle ratings . This shift recognises that high‑speed, spatially detailed pressure data gives insight into injury risk far beyond deformation curves alone.

Why XSensor? 

XSensor’s High‑Speed Impact System captures pressure maps at up to 5,000 fps, resolving thousands of data points across the dummy body. Ultra-thin sensor mats conform to seat belts, torsos, and head restraints—enabling engineers to observe belt shifting, cheek loading, and rib compression with precision. For instance, real‑time monitoring of belt path over the sternum allows quantification of shoulder‑to‑thorax load distribution and detection of belt migration—critical metrics under IIHS 2.0 (ircobi.org). 

Real-world impact on design

Identify risk zones: Shoulder belts have been shown to bear ~5× the load of torso segments; pressure mapping helps redistribute forces via seat belt geometry and restraint tuning .Iterative validation: Rapid data collection (2–5k fps) accelerates design tweaks for airbag, belt, and seat‑back systems—ensuring each component genuinely reduces peak pressure.Global compliance: With Europe and China NCAP aligning with IIHS-style metrics, manufacturers using XSensor systems can future‑proof their platforms ahead of rating changes. 

What should vehicle engineers do now?

Leverage pressure mapping: Integrate high‑speed pressure sensors into standard sled or barrier tests to meet IIHS 2.0 requirements.Tune restraint systems: Use the results to optimise belt anchor points, airbag timing, and seat‑back stiffness—ensuring lower belt-to-body pressure and less rib deflection.Stay ahead globally: As NCAP bodies expand pressure‑based evaluation, those already familiar with XSensor systems will gain a competitive edge in new markets. 

Conclusion

IIHS’s updated protocol marks a turning point: it’s no longer enough to measure acceleration and deformation. High‑speed pressure mapping, as provided by XSensor’s High‑Speed Impact System, is essential. Engineering teams should adopt this technology now—not just for U.S. compliance, but to lead in global safety standards, improve occupant protection, and ensure designs stay competitive.Vehicle impact testing – learn more

Video: The Insurance Institute for Highway Safety is updating its longest-running crash test, the moderate overlap front evaluation, to address a growing gap in the protection provided for front and rear occupants. In the first tests, only two out of 15 small SUVs, the Ford Escape and Volvo XC40, protect the rear occupant well enough to earn a good rating.

Product information:Crash and impact testing with XSensor’s high speed impact pressure mapping system.

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