Start your sled testing project with TÜV SÜD
Discuss your component, test requirements and target markets with TÜV SÜD to define the right sled testing approach.
What are sled tests for crash test simulation?
Sled tests are dynamic tests used to simulate crash loads on vehicle components, seats, restraint systems and interior structures. Instead of carrying out a full vehicle crash test for every development step, sled testing recreates defined crash pulses under controlled laboratory conditions.
TÜV SÜD’s dynamic component testing, also known as DYCOT, combines physical sled testing with virtual simulation to support non-destructive crash test simulation. This gives manufacturers and suppliers reliable data for design optimisation, regulatory preparation and market access.
Depending on the test scope, sled tests can simulate frontal, rear and side impact scenarios. They are commonly used during product development, type approval preparation and conformity of production testing.
Watch DYCOT sled testing in action
See how TÜV SÜD uses non-destructive dynamic component testing and our state-of-the-art sled test technology to simulate realistic crash conditions for vehicle components, seats and restraint systems.
Why crash test simulation with sled tests is important
Non-destructive dynamic testing of components enables original equipment manufacturers to quickly generate robust data under realistic crash conditions. This delivers high quality test reproducibility and repeatability at low service costs, achieving significant savings compared to traditional physical crash testing. The test results support your product development, type approval, and conformity of production testing (CoP).
The resulting reports demonstrate that you have completed extensive crash test simulations to ensure product safety. Those sled tests help you to access global markets by ensuring compliance with relevant international regulations and standards.
How TÜV SÜD supports your testing programme
TÜV SÜD provides a single source of support for dynamic component testing, crash test simulation and whiplash testing. Our technical experts help you plan, set up and carry out sled tests based on your component, vehicle programme, target markets and validation needs.
We can help you:
- Define the right test approach, crash pulses and set-up requirements
- Prepare instrumentation and measurement requirements
- Conduct sled tests under controlled and repeatable laboratory conditions
- Combine physical testing with virtual simulation where required
- Evaluate test data and prepare reports for development, approval or internal quality purposes
- Protect sensitive development prototypes through controlled laboratory processes
Our facilities are designed for complex testing programmes, including parallel customer projects where confidentiality and prototype security are critical.
Whiplash and rear-impact seat testing
Whiplash testing helps manufacturers assess how vehicle seats and head restraints perform during rear-impact conditions. These tests are important for developing safer seat systems and reducing the risk of neck injuries in road traffic accidents.
As part of TÜV SÜD’s DYCOT sled testing services, we support dynamic whiplash tests for seat and head-restraint development. The tests can assess seat geometry, head-restraint position, adjustability, locking mechanisms and overall seat integrity under defined rear-impact crash pulses.
Whiplash test results can support product development, safety validation and preparation for consumer safety assessment programmes such as Euro NCAP and other global regulations. Depending on the programme scope, testing may apply to front and rear seats and can help manufacturers improve occupant protection before final vehicle assessment.
Our latest sled testing technology
Our DYCOT laboratory is equipped with the latest sled test technology:
- IST CSA Advanced Acceleration System (catapult)
- Force 2.5 MN acceleration
- 90g @ 1,000kg / 35g @ 5,000kg, -35g @ 800kg
- Maximum speed 90km/h
- Maximum gradient 14G/MS
- Repeatability 0.5km/h or 1G
- Working stroke 1.7ms
- Low G simulation 5-12G
- Personalised crash pulse iterations
- Reliable EuroNCAP whiplash high standard
- Second seating row whiplash capability
- ENCOPIM Active Lateral Intrusion Simulation System
- Multiactuator simulator of side crashes
- Structural testing structure deformation and sled movement
- Driver and passenger loaded simultaneously
- Side and central airbag development
- HS Vision LED lighting and camera system
- Kistler DAS and sensor system
- In-house dummy family HIII 5% (DTI), 50%(DTI), 95% (DTI), WS (DTI), Biorid-II, Qs
- 2D, 3D static and dynamic photogrammetry,
- 3D Scanning
