Humanetics is a leading manufacturer of automotive crash test dummies, which are humanoid devices utilized in vehicle safety tests to collect data on potential human injury during collisions.
Manufacturing of Physical Components
Humanetics facilities in Huron, Ohio, produce the physical components of these dummies, including skulls, limbs, torsos, and pelvises. These components are engineered to replicate human body parts in both form and function. "Bones" are crafted from metal, while the dummy's spine is made from rubber to achieve a precise level of flexibility. "Flesh" components are manufactured using various materials, including polyurethane for different textures, vinyl that is poured and baked to form skin, and foam to add cushioning. After molding, these parts undergo refinement using tools such as X-Acto knives and sanding belts to ensure smooth surfaces.
Design Principles and Biofidelity
The core design principle of a crash test dummy is biofidelity, meaning it must move and register forces in a manner consistent with a human body. This includes replicating attributes such as head weight and neck flexibility. Dummy designs are developed using data collected from living human bodies and cadaver crash tests. Recent advancements include an updated female dummy design, informed by specific data from female bodies. Previously, "female" dummies were adapted versions of male designs, which resulted in anatomical inaccuracies.
Integration of Electronic Systems
In Farmington, Michigan, electronic components are integrated into the dummies. This process involves the meticulous assembly of numerous sensors, often performed under microscopes. These sensors are designed to accurately measure acceleration, force, and other data points associated with a collision. Calibration of these sensors is a critical step, performed by applying known forces—such as dropping heads from precise heights, striking chests with pendulums, and compressing parts with specialized machinery—to verify data accuracy and consistency.
Crash Testing Procedures
Crash test dummies are advanced instruments, with costs ranging from hundreds of thousands to over $1 million for the newest models. Key customers include automakers, government agencies, and independent organizations such as the Insurance Institute for Highway Safety (IIHS). At test sites, like the IIHS facility in Virginia, dummies are secured in vehicles for controlled collision simulations. To visualize contact points during an impact, engineering technicians apply contrasting paints to the dummy heads. Dummies are designed for repeated use, and ongoing improvements in vehicle safety have reduced the frequency of significant dummy damage during tests.
While virtual testing is increasingly utilized for crash simulations, physical tests remain essential for generating foundational raw data and for organizations like IIHS to establish and publish safety ratings. A typical test involves propelling a vehicle, containing the dummies, into a barrier at a specified speed (e.g., 40 miles per hour) using a hydraulic propulsion system. Following a collision, data from the integrated sensors is processed to evaluate the vehicle's protective performance. The dummies are subsequently cleaned, recalibrated, and prepared for future tests.