Ensured fuel system safety across buses, specialty vehicles, and mobility van conversions by evaluating crash scenarios and optimizing fuel tank placement. Advanced CAE simulations, validated with physical tests, identified and mitigated potential structural impacts, delivering solutions that meet FMVSS 301 and FMVSS 303 across diverse vehicle layouts.

Key Highlights:

• Evaluated both typical aft-of-rear-axle crashes and non-typical fore-of-rear-axle scenarios, identified risks of structural contact with fuel tanks, and developed design modifications to eliminate impact and ensure tank integrity
• Validated high-risk conditions through CAE and supported physical crash testing, achieving strong CAE-to-test correlation
• Addressed mobility van conversions (side-entry and rear-entry) requiring fuel tank repositioning due to accessibility modifications
• Engineered solutions across multiple truck, bus and van tank configurations, including:
  • Underbody mounted systems
  • Aft-of-axle CNG/propane tanks
  • Side-mounted tank layouts
  • Roof-mounted fuel systems
  • Interior compartment tank installations for specialty applications
• Successfully mitigated impact risks and ensured compliance with FMVSS requirements across all evaluated scenarios
• Improved overall vehicle safety by reducing fuel leakage and post-crash hazards