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Crash Test Dummies are the very important tools to evaluate the vehicle safety performance. In order to ensure the dummy performance during the crash tests, the dummy components need to be certificated. In the neck certification procedure, the head angle is the most important parameter, which is the head rotation respect to the neck base. To get the head angle, couples of rotary potentiometers should be mounted either on the calibration fixture or on the dummy head. The rotation is then calculated from those potentiometer readings. There are two potentiometers mounted in the Hybrid III family dummies, while three potentiometers mounted in ES2, ES-2re, SID-IIs, and WorldSid 50th dummies. In the certification, maximum head angle and time occurred should be within certain ranges in the Hybrid III family dummies while for the ES2 and WorldSid 50th dummies, not only the maximum head angle, but also the other angles and their timings should meet the requirements.

The Hybrid III 50th male dummy is widely used in front impact crash tests in the world to evaluate the vehicle safety performance. The chest impact calibration test should be conducted after certain amount of crash tests to ensure that the dummy has the right performance during the crash tests. The impact velocity in the current chest calibration tests is 6.71 m/s and the chest displacement corridor is 63.5 mm to 72.6 mm, which was based on the cadaver tests carried out in 1970s. After over forty years' development, the vehicle safety has been improved significantly with applications of seat belt and airbag technologies. In the European and China new car assessment program (ENCAP and CNCAP), the higher performance limit for the front impact dummy chest compression is 22mm and the lower performance limit is 50 mm, which is much lower than the dummy chest calibration corridor.

The Hybrid III 50th male dummy[1] is used globally in vehicle safety for measuring the damage index of dummy components. This paper focuses on the dummy's ankle structures which have a great effect on its tibia index (TI). It is found that the ankle shaft can be damaged during the regular EURO and China NCAP[2] [3] front offset deformable barrier (ODB) test, which affects the accuracy of TI and the corresponding evaluation score. This paper studies the ankle structure and the component material properties and proposes a design modification to prevent damage to the ankle shaft.

The SID-IIs side impact dummy is a newly designed dummy as an anthropomorphic test device for small size person to be used in side impact crash testing. The head and neck are one of the key components for SID-IIs dummy designing, manufacturing, and testing. This paper is focused on the development of a Headform to be used for neck calibration of the SID-IIs side impact dummy. It will be very difficult in neck calibration measurement of the SID-IIs dummy if its head is used for the test directly. The Headform is one of the methods to solve this problem. However, the Headform must be consistent in achieving equivalent functional performance as the dummy head and associated physical properties. A 3-D head model has been developed for obtaining initial basic information. The offset can be controlled within 3% during the engineering design of the Headform. The neck dynamic test has been done before the Headform test.