NHTSA Upgrades Crash Dummy's Spine and Squishy Face for Realism
Published Date: 9/22/2026
Proposed Rule
Summary
NHTSA is updating crash test rules to include a smarter crash test dummy called the THOR-50M, which better represents an average adult male. They’re asking for feedback on new spine designs and face foam options to make tests more accurate. If you’re involved in car safety or testing, get your comments in by October 22, 2026—this could shape future safety rules and testing costs.
Analyzed Economic Effects
4 provisions identified: 4 benefits, 0 costs, 0 mixed.
Four‑Position Spine Allowed as Optional
NHTSA proposes to allow the Humanetics four-position lumbar spine as a permitted optional configuration for the THOR-50M dummy. If adopted, part 572 would include two drawing packages (one with the original spine and external DAS, and one with the Humanetics four-position spine and an in-dummy DAS), and NHTSA could perform compliance tests using either configuration. The proposed four-position spine aligns with Euro NCAP specifications but would not accommodate the Kistler four-position spine.
New 3D‑Printed Face Insert Option
NHTSA proposes to specify a 3D‑printed thermoplastic polyurethane face insert (drawing 472-1405) as an alternative to the confor face foam (drawing 472-1401) for the THOR-50M. NHTSA testing showed the face insert meets mass/CG/MOI requirements, does not require repeated strikes or a 24-hour recovery period, and demonstrated improved repeatability, durability, and reduced need for replacement—potentially lowering testing and part-replacement costs for users who choose it.
Upper Arm Clevis Durability Update
NHTSA tentatively decided to update the THOR-50M drawing package to include Humanetics' current production upper arm clevis (assembly 472-3831) to address a durability concern. NHTSA testing found the updated upper arm clevis' range of motion and durability acceptable, and NHTSA is not aware of a patent that specifically covers the new clevis design.
THOR‑50M Inclusion Is Voluntary
NHTSA proposes to add the THOR-50M dummy to 49 CFR part 572 but would not require anyone to use the THOR-50M in regulatory or consumer-information crash testing. NHTSA states the amendments would not impose costs on those who choose not to purchase or use the dummy, and users who already own a THOR-50M with the original spine would not need to upgrade.
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Key Dates
Department and Agencies
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