[Report] How Are Car Seats That Withstand Rear Collisions at 80 km/h Made?

Report from Hyundai Transys Seat Research Center on the 5th
Enhanced Safety Testing Including Collision and Airbag Tests
Extreme Temperature Testing from -40°C to 80°C
Development of Next-Generation Mobility Seats for UAM and PBV

"5.4.3.2.1, Bang"

On the 5th, at the Hyundai Transys Seat Research Center in Dongtan, Hwaseong, Gyeonggi-do, a dummy sits inside the 'sled test chamber' where impacts on car seats are tested. When a button is pressed outside the test room, the cart with the dummy seated on it shoots forward like a bullet. This test replicates the moment of a rear-end collision accident where a car traveling at 80 km/h hits from behind. During this test, the moment of impact is captured with a high-speed camera to verify seat safety. Sensors attached to the dummy’s joints analyze the degree of shock applied to the human body at the moment of the accident. Although crash tests are usually conducted at the finished vehicle stage, Hyundai Transys has strengthened crash testing from the stage of manufacturing and researching seats that directly contact passengers.

Hyundai Transys researchers are preparing for a sled test to evaluate the crash safety of car seats.
[Photo by Hyundai Transys]

The research center is also equipped with a seat airbag test chamber. Airbags are installed not only in the vehicle chassis but also throughout the seat. One of the center’s tasks is to check whether the airbags hidden inside the seat deploy properly according to the intensity of the impact. On this day, the center demonstrated the seat airbag test. It was possible to observe the airbags instantly inflating as nitrogen gas was released under impact conditions. When an accident occurs, the driver’s and passenger’s heads often collide, causing injuries, so the role of the seat airbag is crucial in preventing such injuries. Taejin Choi, a senior researcher at Hyundai Transys, emphasized, "While ride comfort is important for car seats in normal times, above all, they must primarily protect passengers at the moment of an accident."

Next, we entered a soundproof studio through two iron doors. Upon entering the massive studio at minus 20 degrees Celsius, a chilling cold was immediately felt. A seat was placed in the center of the studio, surrounded by stand microphones arranged like a spider web. This device measures the noise level generated by vibrations similar to normal driving conditions applied to the seat. The studio can simulate extreme temperature environments ranging from below freezing to 80 degrees Celsius, allowing measurement of seat noise according to temperature and vibration.

Hyundai Transys conducting a composite environmental vibration (BSR) test on a car seat. The seat is placed in a soundproof studio to measure noise caused by micro vibrations.
[Photo by Hyundai Transys]

The durability testing process using robots was also revealed. An industrial robot arm created vibration conditions and repeatedly pressed the seat to conduct durability tests. The vibration test is repeated at least 500,000 times. The robot test that replicates the process of a person getting on and off the seat was impressive. It measures the load generated when a 75 kg person boards and disembarks, and instructs the robot to continuously repeat the same intensity and force distribution. Seats pressed tens of thousands of times by the robot are filmed with special cameras to analyze wear.

Since entering the seat business in 2004, Hyundai Transys has supplied cutting-edge seats for premium models such as the Genesis G90 and G80, as well as high-end models from Hyundai and Kia, and electric vehicle lineups. It has also gained recognition for its technology by supplying seats suitable for electrified vehicles to global electric vehicle startups like Rivian and Lucid. Recently, it has been leading the development of cabin concepts for urban air mobility (UAM), autonomous driving, and purpose-built vehicles (PBV), focusing on designing interior spaces for next-generation mobility. In particular, it is dedicated to developing eco-friendly materials that increase the proportion of natural materials, reduce harmful substances, and enhance flame retardant performance. Junho Song, head of the Seat Materials Research Team, said, "We not only develop eco-friendly materials themselves but also research eco-friendly seats through various methods such as using eco-friendly adhesives and developing processes that minimize waste in seat perforation."

UAM (Urban Air Mobility) design solution developed by Hyundai Transys
Photo by Hyundai Transys

This content was produced with the assistance of AI translation services.