Welcome to the Federal Outdoor Impact Laboratory (FOIL), where researchers use state-of-the-art science equipment to study motor vehicle crashes. The experiments conducted here improve understanding of the dynamics of a collision by measuring the resulting impact, confirming computer-generated predictions, and aiding in the development of mathematical models. Ultimately, safety is the primary focus of FOIL.

A pendulum tower is also among the equipment available at FOIL. It enables collision impact studies on a range of components of barrier systems, like walls and guardrails, intended to lessen the severity of crash impact. This component-level testing can be achieved through a drop test method or by the use of two swingable weights representative of both a small passenger vehicle and a large pickup truck moving at a speed of 25 mph. The pendulum allows for component-level testing at a reduced cost and shorter schedule.

The pendulum pit below the pendulum tower provides flexibility to test many different hardware and barrier components. Previous tests involved guardrail posts, roof crushes, mailbox and sign supports, cable strength tests, and vehicle component tests (e.g., engine mounts, suspension, and windshield damage).

Before any vehicles are sent down the track, the FOIL researchers run multiple computer-generated simulations to determine the most likely outcome of crash events. The Finite Element Simulations start with a scan of every component of the test vehicle to create a digital model.  

By taking multiple factors into account, including vehicle type, speed, impact angles, and design details, there are very few surprises when the live tests occur.

The propulsion system—the first of its kind in the United States—is also known as the vehicle accelerator. It pulls the driverless vehicle down the track to a collision. It utilizes compressed hydrogen stored in a large cylinder array to propel two large pistons that flow hydraulic fluid through two large turbine motors. These turbine motors then use their rotational motion to pull a trolley that is directly attached to the test vehicle.

Full-scale vehicle crash tests are conducted using the laboratory's vehicle accelerator. This hydraulic cable system can accelerate an 18,000-pound truck to more than 50 mph in just 220 feet.

Test vehicles simulate a collision by being pulled down a hollow aluminum track.

These photos are cross sections of the track system on which the test vehicle slides.

The runoff area is where test vehicles decelerate after a crash test. The laboratory also has an impact area that provides ample room for the construction of various types of roadside hardware installations.