Exploring Safety Standards Part 2: A Guide to FMVSS 200 Series

The Federal Motor Vehicle Safety Standards (FMVSS) outline requirements for vehicles to be sold in the United States, which are enforced by the National Highway Traffic Safety Administration (NHTSA). There are several categories of FMVSS tests, and those that MGA conduct include:

Ø  The 100 series tests, which define the crash avoidance features of the vehicle.

Ø  The 200 series tests that define crashworthiness requirements.

Ø  The 300 series tests, which define post-crash survivability requirements.

In this second installment of a three-part series, we will be taking a deeper dive into the FMVSS 200 series level tests supported at MGA. For decades, MGA has been contracted by the NHTSA to perform FMVSS compliance testing as well as the New Car Assessment Program (NCAP). The test contracts held by MGA include many FMVSS tests from all three series listed above.

Beyond crash testing, federal vehicle safety regulations for passive safety components are commonly known as the FMVSS 200 Series. These regulations focus on occupant injury prevention and crashworthiness, ensuring vehicles meet established safety standards. The FMVSS 200 Series testing includes multiple test types: quasi-static structural strength tests, dynamic impact tests, dynamic sled tests, and full vehicle crash – all designed to evaluate a vehicle’s ability to protect occupants in a crash. MGA offers a wide range of FMVSS compliance testing services, supporting the industry’s commitment to safer vehicles. The tests highlighted here involve full vehicles or vehicle subsystems such as seats, instrument panels, and airbags. A few other 200 series tests not included here evaluate sub-components such as seat belts, child seats, and glazing.

FMVSS 200 Series Integration

As safety regulations have evolved, so has the automotive industry’s approach to FMVSS 200 series compliance. Advancements in materials science, computer modeling, and sensor technology have influenced how manufacturers design and test vehicle structures. High-strength steels, aluminum alloys, and composite materials have enhanced vehicle crashworthiness, requiring updated testing methodologies to assess their real-world performance. In addition, the use of finite element analysis (FEA) simulations has enabled manufacturers to predict testing outcomes before physical testing, improving efficiency and reducing development costs. These innovations, combined with stricter safety regulations, have driven the industry toward more precise and data-driven testing strategies.

MGA Research Corporation has steadily enhanced its FMVSS 200 series testing capabilities to keep pace with industry developments. The integration of high-speed cameras, advanced crash test dummies, and data acquisition systems has significantly improved the accuracy of test results, allowing for deeper insights into occupant safety. Additionally, the use of dynamic sled testing with vehicle-specific acceleration profiles has enabled a more controlled evaluation of restraint systems and impact forces. By keeping up with technological advancements, MGA provides manufacturers with reliable testing solutions that support compliance with evolving safety standards and contribute to the improvement of vehicle crashworthiness and occupant protection.

MGA’s current FMVSS 200 series supported testing includes:

Component Level Test Standards

FMVSS 201 Occupant Protection in Interior Impact - This standard uses a dynamic impactor with a simulated headform to impact various components in the occupant compartment to measure the head injury level.

FMVSS 201U Upper Interior Occupant Protection - The Free-Motion Headform test system is used for conducting occupant head impact simulations on the vehicle’s upper interior. 

FMVSS 202a Head Restraints – This standard determines a seating system’s ability to protect a seated occupant from injury in a whiplash condition, i.e., low-speed rear end collision. The manufacturer has the option to test statically or dynamically for compliance.

FMVSS 203 Protection Against Steering Wheel Impact – This standard is used to evaluate potential driver chest injuries in a frontal crash simulation. It is currently exempt for vehicles that meet specific sections of the FMVSS 208 crash standard.

FMVSS 206 Door Latches and Hinges - This standard has several compliance tests related to door systems, door latches, and hinge components. Each test is used to evaluate the door system or component’s ability to withstand specific forces and not open.

FMVSS 207 Seating Systems - This standard requires seats to be evaluated in various loading conditions to ensure that the seat back stays in its proper place in the event of a crash. In the case of seat belts anchored to the seating system, a combined 207/210 test is conducted.

FMVSS 210 Seat Belt Anchorage Systems - This standard involves a combined loading strength test to evaluate the strength of seating systems and their seat belt anchorage. It uses fixtures representative of a human torso and lap to apply loads simulating a frontal crash. Recently, NHTSA published a potential change which allows manufacturers to comply with their choice of loading devices.

FMVSS 214S Side Door Intrusion – This standard uses a 10” pole fixture and pushes into the door structure until a specific load, energy, and displacement are achieved. This is considered a destructive test, and its goal is to prevent door openings to prevent occupant ejection.

FMVSS 216a Roof Crush - This standard simulates a rollover crash event and aims to prevent the deformed roof structure from contact with the interior occupants thus avoiding an occupant being trapped in a vehicle following a rollover.

FMVSS 225 Child Seat Anchorage Systems – This standard evaluates a seating system’s ability to provide sufficient protection with an add-on child restraint system attached. Simulating crash events from the front and side, child seat fixtures are used to apply loads to the CRS LATCH system for each occupant seating position.

FMVSS 226 Ejection Mitigation – This standard is used to evaluate countermeasure designs for side curtain airbags, glass, and other subsystems, that are intended to reduce occupant ejection in rollover or side impact events.

Full Vehicle Crash Standards

FMVSS 208 Occupant Crash Protection - This standard is used to test the effectiveness of occupant restraint systems, including airbags and seat belts, in protecting occupants in various crash scenarios. Several FMVSS can also be evaluated during certain 208 crash tests including: FMVSS 204 Steering Control Rearward Displacement, which evaluates the rearward displacement of the steering column in a frontal crash to minimize the risk of injury to the driver; FMVSS 212 Windshield Mounting, which evaluates the retention of the windshield during a crash to ensure it remains in place, contributing to occupant containment and structural integrity; and FMVSS 219 Windshield Zone Intrusion, which is used to assess the potential for vehicle components to penetrate the windshield area during a crash, ensuring driver visibility and occupant protection.

FMVSS 214 Side Impact Protection - This standard evaluates a vehicle’s ability to protect occupants in a side impact collision by assessing structural integrity and occupant injury criteria using dynamic crash tests.

Navigating the evolving landscape of automotive safety requires an experienced partner in FMVSS 200 Series compliance. As automakers incorporate new materials, designs, and technologies, maintaining compliance with federal safety standards remains an important priority. With decades of experience in vehicle homologation and active involvement in safety regulatory bodies, MGA provides the testing, insights, and guidance necessary to help manufacturers meet these evolving requirements.

Ready to ensure your vehicles meet FMVSS 200 Series standards? Contact us today to learn how MGA can support your safety testing needs.