Are EV’s Safer in a Crash?

Are EV’s Safer in a Crash?

Are EV’s Safer in a Crash?
DTS FMVSS305 New High Voltage Recording Device for New Energy Vehicles - Electric Vehicle Testing

Electric vs. Gas: Which Vehicles are Safer? 

Navigating New Features, Functions, and Global Safety Requirements

Electric and hybrid electric vehicles (EVs/HEVs) frequently outperform internal combustion engine vehicles in safety ratings, driven by design advantages such as a low center of gravity, larger crumple zones, and integrated electronic speed controls. These features enhance crash energy management and vehicle stability.

However, the shift to electrification introduces new technical challenges, particularly in crashworthiness validation and post-crash safety. High-voltage systems pose risks to occupants and emergency responders, necessitating rigorous testing under FMVSS305 and similar global standards.

Why EVs Can Be Safer:

  • Lower center of gravity: Due to battery placement, reducing rollover risk.
  • Larger crumple zones: No engine up front allows better energy absorption in frontal crashes.
  • Advanced safety features: Many EVs come with the latest ADAS (Advanced Driver Assistance Systems).
  • Remote speed control: Some EVs allow setting and monitoring top speeds remotely — ideal for teen drivers or fleet monitoring.
  • Higher safety ratings: Several EVs (like the Tesla Model Y or Ford Mustang Mach-E) score top marks in IIHS and NHTSA crash tests.

Potential Risks with EVs:

  • High-voltage shock: Post-crash electrical isolation is critical to occupant and first-responder safety
  •  Fire risk: While rare, battery fires can be harder to extinguish than gasoline fires.
  • Thermal runaway: Heat buildup can lead to explosions in severe impacts.
  • Heavier weight: EVs tend to be heavier, which can increase injury risk to occupants in lighter vehicles during collisions.
  • Unexpected acceleration: EVs can accelerate quickly, catching some drivers off guard, especially inexperienced drivers

The Federal Motor Vehicle Safety Standard FMVSS305 focuses on post-crash safety for EVs. The standard mandates a minimum level of electrical isolation between the high-voltage system and the vehicle’s chassis. The goal is to isolate any electrolyte spillage from propulsion batteries to ensure occupants and first responders are protected from high-shock sources, especially following a crash.

EV Crash Test Photo Credit IIHS

Meeting New Testing Requirements
With new technology comes the need for new testing protocols and equipment. In response to customer requests,  DTS introduces the new FMVSS305 high-voltage recorder for testing EV and Hybrid new energy vehicles (NEVs). The DTS FMVSS305 allows for remote measurements, making it ideal for use with the 301 static rollover system.

FMVSS305 High-Voltage Recorder
The DTS FMVSS305 is a high-voltage isolation measurement system for electric and hybrid vehicle testing. It provides a safe and reliable way to capture battery and drive system voltages up to ±1,200-volts. The unit is designed to be used standalone or can be seamlessly integrated into TDAS or SLICE data acquisition systems via DataPRO Software. For more information, click Learn More.

The bottom line, based on all the data and safety testing, there’s no absolute winner between EVs and gas vehicles. Electric vehicles are generally as safe or safer than gas-powered vehicles, but as the fine print always says . . . it depends on the model and type of crash.

DTS TSR AIR Data Recorder

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Engineering Hall of Fame Inducts Tim Kippen

Engineering Hall of Fame Inducts Tim Kippen

Engineering Hall of Fame Inducts Tim Kippen
DTS - Tim Kippen - Cal Poly Pomona Engineering Hall of Fame 2025

DTS Co-Founder Tim Kippen Inducted into Cal Poly Pomona Engineering Hall of Fame

Diversified Technical Systems (DTS) is proud to announce that co-founder Tim Kippen has been inducted into the Cal Poly Pomona College of Engineering Hall of Fame. This prestigious honor recognizes Tim’s exceptional contributions to the field of engineering and his outstanding professional achievements.

The induction ceremony, which included family, friends and many DTS employees, was co-emceed by fellow DTS co-founder and 2019 Hall of Fame inductee Mike Beckage. The evening was filled with inspiring stories from students and inductees, highlighting the impact of Cal Poly Pomona’s engineering program.

The connection between DTS and Cal Poly Pomona runs deep. Tim and Mike’s story began in a classroom at CPP, where they discovered a shared mindset that would shape the early culture of DTS. The university’s “learn by doing” philosophy, emphasizing hands-on learning, became a cornerstone of DTS’s collaborative environment.

DTS’s success over the last three decades has been significantly shaped by the contributions of many Cal Poly Pomona graduates. The DTS team continues to actively support CPP engineering students through mentoring events, DTS facility tours, training events, and a generous gift of DTS hardware to inspire ongoing student R&D and engineering projects.

Tim’s induction, alongside nine other distinguished alumni in the 2025 Hall of Fame class, celebrates his significant contributions to the engineering community and the success of DTS. His journey, rooted in the values of Cal Poly Pomona, serves as an example of how dedication and innovation can lead to remarkable achievements. Congratulations Tim on this well-deserved honor!

DTS - Mike Beckage & Tim Kippen - Cal Poly Pomona Engineering Hall of Fame

Mike Beckage with Tim Kippen

DTS - Tim Kippen - Cal Poly Pomona Engineering Hall of Fame - Jacket Presentation

Jacket Presentation

DTS - Group photo - Tim Kippen - Cal Poly Pomona Engineering Hall of Fame Event

DTS Group Photo

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NASA Spinoff – Better Data for Bodies in Motion

NASA Spinoff – Better Data for Bodies in Motion

NASA Spinoff – Better Data for Bodies in Motion

Better Data for Bodies in Motion

A wearable device to monitor astronauts’ tumultuous return to Earth is helping industry

The DTS Story: In 2019, NASA’s Johnson Space Center in Houston selected DTS for a Small Business Innovation Research (SBIR) project to develop a wearable data recorder for astronaut spacesuits. DTS developed the Dynamic Kinematic Recorder (DKR) for NASA. That technology was then spun off to create the TSR AIR data logger, which is now used for a variety of applications including flight testing and tracking high-value shipments like satellites.

The return to Earth is a rough ride for astronauts, from the violent turbulence of atmospheric entry to a jarring landing. Hitting the ground in a Soyuz capsule is the equivalent of driving a car backward into a brick wall at 20 mph, and it’s resulting in more head and neck injuries than NASA computer models predicted. To collect more data, NASA’s Johnson Space Center in Houston commissioned a Small Business Innovation Research (SBIR) project to develop a wearable data recorder for astronaut spacesuits. One result, created by Diversified Technical Systems Inc. (DTS), is a miniature commercial device that now collects and transmits data for any application from airplane test flights to tracking high-value shipments.

Common data recorders, such as those used for laboratory testing and automotive crash testing, can be bulky and require external power sources. But even smaller versions of that technology weren’t going to work for astronauts, according to Nate Newby, occupant safety analyst at Johnson. The occupant protection tools NASA uses to predict the likelihood of injury under the unique conditions of capsule landings require kinematic measurements defining the motion of a body through space.

“Our predictive tools were adapted from the automotive world and from the military,” he said. “But our environment is a little bit different.” The head and neck are subjected to high rates of acceleration in every direction. The kind of injuries astronauts are prone to don’t occur under other conditions, so NASA had to fill that data gap to improve the predictive model.

DTS already had extensive experience in miniaturizing data recorders, including one data logger that’s embedded in the mouthguard worn by NFL players. NASA engineers worked with the company to adapt that technology and refine it during Phase I and II SBIR projects.

Astronaut Safety

DTS’s work to create a self-contained wearable device that didn’t rely on a wired data connection and was powered by an integrated battery benefited from the agency’s experience with space travel — including proven materials, knowledge of conditions that affect battery longevity, and more. The housing had to contain the hardware and software necessary to take and store motion measurements, with enough room for the power source and wireless communications technology. The project envisioned a small data recorder that could attach to an astronaut’s communications cap and automatically begin recording data when it reached a predetermined velocity.

“The astronauts are in the spacecraft for a while, and you don’t want it to record that whole time, to minimize power and storage,” said Newby. To meet NASA’s specifications, the company needed to gather data about the kind of acceleration astronauts experience and use that information to create a mechanism that could automatically record both launch and re-entry forces.

DTS started with its core technology, designed to capture data for “dynamic testing,” primarily crash, blast, and injury biomechanics testing, according to Mike Beckage, the company’s CTO. The existing hardware and software provided reliable shock and vibration data, which NASA, a DTS customer, already relied on for a variety of aeronautics and aerospace testing.

The agency used this off-the-shelf technology to verify the structural integrity and occupant safety of the Orion crew capsule. Newby also uses a DTS device to collect data from hard landing crash tests performed using test dummies. This work and more helped the Seal Beach, California-based DTS, a brand of Vishay Precision Group Inc., build a good working relationship with NASA for over 20 years.

“A development project like this is a very interactive process, so we had regular meetings to discuss our progress. We identified technology and capabilities that we could build into the product,” said Beckage. Tapping NASA’s expertise was challenging as the COVID-19 pandemic disrupted much of the project, but the company still met the final deadline.

Parachute Drops and Car Crashes

The prototype design, named DXR, met every specification except for size — it’s still a little too big for NASA’s applications. But Beckage said the company based its new TSR AIR data logger on the DXR design. NASA input on everything from new features to the final design made the 2.75-square-inch device ideal for numerous commercial applications.

Adding the TSR AIR to a tailfin or other places on an airplane makes it possible to collect in-flight data. It can also be attached to a trailer transporting high-priority cargo, not only tracking its location in real time but recording the conditions of that trip. The device has wireless charging and wireless communications capability, making it easy to keep powered and to continuously share data.

Safety testing that includes drones, parachute drops, and automobile crashes can also use the device. It can be used to track batches of pharmaceuticals as they go through production lines and the shipping process to provide information about exposure to environments that can degrade medicines as they’re moved around.

In addition to providing an array of hardware, DTS provides the services necessary to help companies get their applications up and running. Beckage said he hopes to continue integrating what the company learns from NASA technologists, serving as a conduit for sharing that store of knowledge.

“We’re thankful to have those opportunities to work on really cool applications for NASA and redefine what’s possible when it comes to testing,” said Beckage.

Astronaut Anne McClain returns to Earth after 204 days in space, a duration that weakens bones and muscles. To better understand how the velocity of descent and landing can cause head and neck injuries, Diversified Technical Systems (DTS) created a wearable data recorder. Credit: NASA

A “soft” landing in a Soyuz capsule is like driving a car in reverse into a brick wall. To help NASA gather information about the cause of head and neck injuries experienced by astronauts, DTS developed a wearable miniature data recorder. Credit: NASA

DTS TSR AIR Data Recorder

The TSR AIR data recorder measures the velocity and motion of an object. DTS created a wearable version for NASA, but now industry uses the device for safety test flights, tracking the location of high-values assets, and more.

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Embedding the data acquisition into the test article minimizes exposed cables throughout the leg and eliminates any trailing cables that could affect the launch.  DTS offers a complete turnkey solution engineered to maintain proper mass, center of gravity and moments to help advance pedestrian safety testing.

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