Tesla Model S achieves best-ever crash test score

Palo Alto, August 21, 2013: Independent testing by the National Highway Traffic Safety Administration (NHTSA) in the USA has awarded the Tesla Model S – a full-sized electric four-door saloon -- a 5-star safety rating in every subcategory. Approximately one percent of all cars tested by the US government achieve 5 stars across the board. While NHTSA does not publish a star rating above 5, the Model S has achieved a new combined record of 5.4 stars.

Of all vehicles tested, including every major make and model approved for sale in the United States, the Model S set a new record for the lowest likelihood of injury to occupants. While the Model S is a saloon, it also exceeded the safety score of all SUVs and minivans. This score takes into account the probability of injury from front, side, rear and rollover accidents.

The Model S has the advantage in the front of not having a large petrol engine block, thus creating a much longer crumple zone to absorb a high-speed impact. This is fundamentally a force over distance problem – the longer the crumple zone, the more time there is to slow down occupants at g loads that do not cause injuries. The Model S motor is only about a foot in diameter and is mounted close to the rear axle, and the front section that would normally contain a petrol engine is used for a second trunk.

For the side pole intrusion test, considered one of the most difficult to pass, the Model S was the only car in the ‘good’ category among the other top one percent of vehicles tested. Compared to the Volvo S60, which is also 5-star rated in all categories, the Model S preserved 63.5 percent of driver residual space compared to. 7.8 percent for the Volvo. Tesla achieved this outcome by nesting multiple deep aluminum extrusions in the side rail of the car that absorb the impact energy and transfer load to the rest of the vehicle. This causes the pole to be either sheared off or to stop the car before the pole hits an occupant.

The rear crash testing was particularly important, given the optional third row children's seat. For this, the Tesla factory installs a double bumper if the third row seat is ordered. This is needed in order to protect against a highway speed impact in the rear with no permanently disabling injury to the third row occupants. The third row is already the safest location in the car for frontal or side injuries.

During rollover tests, the NHTSA employed special measures to induce a roll due to the Model S’s particularly low centre of gravity. Tesla mounts the battery below the floorpan. It says tests show that four fully loaded Model S vehicles could be placed on top of an owner’s car without the roof caving in.