It takes massive computing power, expensive dummies and about 600 full-scale crash tests a year to ensure Ford and Lincoln vehicles meet safety standards for every market in the world.
In addition to preparing the dummies, the crash vehicle is painted to highlight critical elements, said Jill Lauffer, manager of the body and chassis test lab. Sensors, accelerometers and high-speed cameras are installed to capture as many as 30 different views of the crash and measure the forces of the impact.
And that is only the tip of the iceberg. Engineers spend weeks running thousands of computer simulations before a car is launched at 30 miles per hour into a wall
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