The headliner is often labeled as one of the largest, uninterrupted piece of trim in a vehicle, and frequently demands attention. Beyond its role in beautifying the roof of a vehicle, headliners also serve as a cover for vehicle infrastructure and a framework for overhead systems. Neatly tucked behind and integrated into most modern headliners are curtain airbags, electrical systems, and safety components. Taken together, these systems mean that headliners must undergo a wide array of tests. 

From component-level material to full-vehicle durability, our testing capabilities go beyond just aesthetics. Over the last 40+ years, MGA Research Corporation has supported customers in headliner testing to ensure safer vehicles on the road.

Type of Testing 

Headliner (including the overhead system) testing can be divided into a few distinct categories. These include:

• Material testing
• Component durability testing
• Safety testing 

Each category has its own set of requirements and is also loosely divided along testing responsibilities, from Tier 2 to OEM responsibilities. At MGA, we can leverage our decades of experience and comprehensive equipment base to support nearly all of these tests.

Materials Testing for Headliner Daily Use

Headliners are among the largest single trim pieces in a vehicle, and their appearance is of utmost importance. Although they are touched less than other contact surfaces in a vehicle, the materials used must still withstand daily use. This means a thorough evaluation of their appearance-based properties should be performed. Below is a brief list of tests often performed during validation; see more on our Materials Capabilities page: 

• Soil & Cleanability 
• Resistance to Fluids ‍
• UV Degradation 
• Rot/Mildew Resistance 
• Fogging 
• Abrasion/Wear 

Component Durability Testing for Headliner Lifecycle

Moving a step from material level evaluations is component durability testing. This testing encompasses the life of the headliner and its behavior as a whole. These tests are often carried out either in a provided vehicle or a custom fixture, like MGA’s headliner carts. Using vehicles or purpose-built fixtures allows for realistic boundary conditions when evaluating properties such as dimensional stability, sag, stiffness, and strength.

Many of these tests include aging the headliner at extreme temperatures using large environmental chambers and performing evaluations afterwards. Examples of component durability tests are: 

• Dimensional Stability 
• 3D scanning, gaps and sag 
• Environmental Testing 
• Stiffness/tactile response 
• Component Retention 
• Adhesion (Peels) 

Occupant Safety Testing on Full-Vehicle Level

The final group of tests are related to occupant safety and are performed on a vehicle level. These tests include airbag performance and head impact. While not required, most modern vehicles have curtain airbags tucked behind the headliner or pillar trim. Due to the location of the airbag, it is necessary to perform deployments with a full headliner installed in the vehicle to ensure proper deployment. 

MGA supports this testing in multiple ways including standard deployments as well as FMVSS 226 Ejection Mitigation testing using our in house-built system. The Free-Motion Headform System (FMH) system is also used to support FMVSS 201u testing on headliners. This testing is performed to simulate occupant head impact on the vehicle’s upper interior, thus evaluating the energy absorption/attenuation properties of the headliner. 

The MGA Advantage 

Whether it be a simple cleaning test or a lifesaving airbag test, MGA is fully capable of supporting the tests required for headliners and overhead systems. Being our own test equipment manufacturer for FMVSS 201u and 226 testing; this expertise helps ensure a smooth testing experience.

Beyond equipment, we've developed flexible carts for the explicit purpose of testing headliners without the need for hard-to-obtain vehicles by fabricating custom fixtures in-house. With multiple labs equipped to support materials and component durability testing, we can support larger programs by leveraging our network of laboratories.

To request more information about our headliner testing or to get in contact with one of our engineers, reach out to us at www.mgaresearch.com/contact.

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