Vehicle & Road Safety

At VIRTUAL VEHICLE, we’ve been dedicated to enhancing road safety since 2004.

Enhanced crash structures and passive safety systems, along with automated driving functions and driver assistance systems, are vital for safeguarding vehicle occupants and vulnerable road users.


VIRTUAL VEHICLE has been dedicated to advance road safety. Our research focuses on battery technology, occupant safety, VRU protection, and method development in connection technology and bio-based materials.

Central Research Topics

  • Improve the safety of vulnerable road users (VRU)
  • Improve structural design and crash simulation
  • System simulation for all road users, vehicles and the environment to increase the safety of electric vehicles and enable new electric vehicle concepts


Battery Crash Safety


  • Mechanical modelling


  • Vehicle integration


  • Mechanical testing


  • Multi-physic coupling


  • AI / ROM methods

Structural Design & Crash Simulation

Improved predictability of crash simulation (L2 Tool)


  • Efficient meta models for localized structural failure under crash loads
  • Risk assessment of crack initiation
  • Integration in the vehicle development process

VRU Protection Systems


Identification of the optimal system combination to minimize accidents


Integrated tool chain for simulating any number of accident scenarios

Materials & Lightweight


Hybrid Materials and Fiber Reinforced Plastics


Lightweight Structural Safety FE-Methods Development


Process Chain Mapping for Structural Safety Simulations (Metals and Plastics)


Bio-based Materials and Function Oriented Process Control Integration

The Field of Materials and Lightweight

The organization employs Finite Element (FE) simulation to predict mechanical behavior, develop new methods for lightweight structural safety assessment, integrate process chain mapping for efficient simulation workflows, and optimize manufacturing processes of bio-based materials with function-oriented process controls.

Battery Crash Safety

Mechanical models can be used to virtually predict a mechanically induced short circuit. All types of battery cells – cylindrical or prismatic hard case and pouch – can be modeled…

VRU Protection Systems

Protecting vulnerable road users (VRUs) like pedestrians, cyclists, and vehicles is paramount in road traffic. However, determining the most effective system or combination of systems to minimize VRU injuries in real-life conditions poses challenges due to the vast possibilities and the need for early product development insights.


VIRTUAL VEHICLE’s method addresses this by enabling the evaluation of active, passive, and integrated VRU protection systems using identical injury criteria through simulation. This comprehensive approach, featuring an end-to-end tool chain for simulating various accident scenarios, facilitates the identification of optimal VRU protection configurations, enhancing road safety for all.


Structural Design and Crash Simulation

Predicting structural failure in vehicle crashes remains a significant challenge in virtual vehicle development, especially with the increasing use of lightweight materials and innovative joining techniques, which heightens material variety and structural complexity. Robust calculation methods are crucial for managing this complexity and ensuring reliable prediction results.


VIRTUAL VEHICLE’s L2 tool offers a modular framework that accurately models material failure under localized stress without compromising computing efficiency. Central to this methodology are efficient metamodels that consider relevant production and joining processes. Developed in collaboration with partners like VW, Audi, and Magna since 2004, this methodology has become an integral component of the industrial vehicle development process.


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LIghtweight Battery System for Extended Range at Improved SafeTY

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In this project, an alternative approach for the improved simulation of crack propagation by continuous element elimination is pursued.

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The main objective of this project is to develop and test an interdisciplinary evaluation method for battery systems for the holistic assessment of thermal safety.

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Use Cases

Further Topics

Future car


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