Top 10 safty standrads in
automotive plastic trim design
using catia V5
ENSURING SAFTY AND
COMPLIANCE IN DESIGN
NAME – SURAJ PANJA
INTRODUCTION
Off late, due to various Government measures and car
crash test organizations like Global New Car Assessment
Program (GNCAP) which publishes car safety ratings,
many car buyers have finally understood the importance
of having a car which has a solid build quality with
added safety features
Basically, car safety is
categorized into:
1. Active Safety
2. Passive Safety
Active Safety
Passive Safety
As the term denotes, it plays It comes into play when a
an active role in keeping crash has occurred.
your car safe and reduces Passive safety systems
the chances of a crash. It prevent the driver and
constantly monitors one or passengers from getting
more aspects of your car injured by reducing the
for potential risks. Some of impact of the crash. Some
the common active safety of the common passive
features include Anti-lock safety features are
braking system (ABS), seatbelts, airbags, ISOFIX
Electronic Stability Control mounts, crumple zones,
(ESC), Tyre Pressure etc… Keep in mind that the
Monitoring System (TPMS), majority of passive safety
Lane Departure Warning systems work only when
System (LDWS), etc. you wear your seatbelt.
MATERIALS SELECTION AND
IMPACT RESISTANCE
FMVSS 201
This Standard applies to MPVs, trucks and buses with a GVWR
or 10,000 lbs. (4,536 kg) or less. It establishes requirements
for the use of energy-absorbing materials on the interior
components such as instrument panels, seat backs, interior
doors, armrests and sun visors.
ECE-R21
The regulation ECE-R 21 contains the "uniform provisions
concerning the approval of vehicles with regard to their interior
fittings". A part of this regulation contains defaults for the
arising deceleration for an occupant head by impacting
structure parts of a cockpit.
1. Foam Padding
Foam padding is a lightweight, compressible material often
made from polyurethane or polyethylene foam. It is used
extensively in automotive trims and interior surfaces
Contribution to Injury Reduction:
Energy Absorption: Foam padding is effective at absorbing and dissipating impact
energy. During a collision, it compresses under force, reducing the peak impact
force transferred to occupants.
Cushioning Effect: The cushioning effect provided by foam padding helps to
prevent direct contact with hard surfaces, reducing the risk of injury from sharp
impacts.
Customizable Density: Different densities and types of foam can be used
depending on the required level of protection and the specific application within
the vehicle.
Example:
Foam pads used in
door panels, headliners, and armrests provide cushioning and absorb impact
forces, enhancing overall occupant safety.
2. Energy-Absorbing Plastics
Energy-absorbing plastics are specially designed
polymers that can deform under impact. These
materials include certain grades of polypropylene
and polycarbonate blends.
Contribution to Injury Reduction:
Deformation Characteristics: These plastics are
engineered to deform and spread the impact force
over a larger area. This deformation absorbs and
reduces the energy that would otherwise be
transmitted to the occupant.
Durability: They maintain their structural integrity
while absorbing energy, providing a balance
between protection and durability.
Example:
Energy-absorbing plastics are often used in
dashboards and console panels to provide a safer
interaction zone in the event of a collision.
MATERIAL IMPACT RESISTANCE USING CATA
V5 SIMULATION TOOLS
Establish what you aim to achieve with the simulation,
such as impact resistance, energy absorption, or
material deformation
3. Honeycomb Structures
Honeycomb structures are made from lightweight
materials with a hexagonal cell structure, often from
aluminum or polymer-based composites.
Contribution to Injury Reduction:
High Energy Absorption: The honeycomb structure is
designed to absorb significant amounts of energy while
maintaining a low weight. It collapses under impact,
absorbing and dissipating energy effectively.
Structural Support: It provides excellent impact
resistance while also supporting structural components,
helping to protect the vehicle's interior from severe
impacts.
Example:
Honeycomb materials are used in areas such as
dashboard panels and lower interior components where
high-impact resistance is needed.