Comprehensive crash validation of a battery electric vehicle with an aluminum body against C-NCAP crash standards and FMVSS 207/210/225 requirements. A full FE model was built and tested for crash safety, durability, and occupant protection.

Key Highlights:

• Developed full FE model: BIW, battery enclosure, suspension, sub-frame, IP, steering, under-hood.
• Simulated: CNCAP Full Frontal, 40% ODB, IIHS Side Impact, FMVSS 214 Oblique Pole.
• Performance checks: front rail crush management, crash pulse, survival space intrusion, battery box protection.
• Hood mapping: impact zones, stiffness, hinge/latch, and leg-form catcher.
• Improvement: increased thorax airbag-to-trim clearance for reliable deployment.
• Result: Significant gains in occupant protection and structural performance, validating aluminum EV design.