When the dust settles, the result is clear: despite the force of the collision, the truck’s high-voltage battery system and electrical components remain intact. For developers, that outcome marks a milestone in proving that electric long-haul trucks can meet the same safety expectations as diesel models. And perhaps even exceed them.
Crash-tested like a diesel but with new challenges
Mercedes-Benz Trucks’ internal accident research team had been involved in the eActros 600 project from the start. Drawing on real-world accident data, the team identified typical heavy-duty crash scenarios, especially frontal and side impacts, and tailored the truck’s structure to address them.
- A reinforced cab with defined energy absorption zones that redirect crash forces through impact-optimised structures.
- A heavy-duty frame architecture developed specifically for electric long-haul trucks, ensuring the high-voltage battery housing remains stable even under severe deformation loads.
- Integrated airbag systems and seatbelt tensioners across all cab variants to enhance occupant protection.
“The mechanical stress was high – but our concept works reliably,” said Frank Müller, Head of Accident Research & Passive Safety at Mercedes-Benz Trucks, after the Neumünster test.
The side-impact scenario was chosen to replicate one of the most dangerous accident types for heavy vehicles. The crash confirmed that the battery housing showed no critical deformation, preserving the driver’s survival space even under extreme conditions.
Inside the crash lab
Every crash test is the culmination of months of simulation-based analysis. Before impact, dozens of sensors are installed and calibrated to measure forces, deformations, and thermal responses across the truck.
“For me personally, the last two to three minutes before the crash are particularly fascinating,” said Christoph Berger from the Passive Safety team. “Everything becomes quieter than before, and there is a concentrated tension in the air.”
Photo credits @ Daimler Truck
When the test sequence triggers, the noise and violence are immediate — but the data is gold. Following each test, emergency specialists perform a safety release check to ensure there are no live electrical hazards before engineers dismantle the truck for a detailed damage analysis.
Photo credits @ Daimler Truck
High-voltage system built for extreme resilience
The eActros 600’s high-voltage (HV) system is designed around three lithium iron phosphate (LFP) battery packs, each rated at 207 kWh, providing a total installed capacity of 621 kWh. LFP chemistry offers long cycle life and a usable capacity above 95% — meaning more of the battery’s stored energy can be accessed compared to other chemistries.
The system meets stringent internal standards for insulation, mechanical strength, and fire protection, exceeding current legal requirements. After a severe crash, these safety measures help prevent electrical hazards and thermal events, protecting not only the driver but also emergency responders and bystanders.
Photo credits @ Daimler Truck
Production vehicles, Mercedes-Benz says, must pass brand-specific crash tests that go beyond EU regulatory requirements. The manufacturer aims to ensure durability equivalent to a conventional diesel Actros — up to 1.2 million kilometres in ten years of operation, with the battery retaining over 80% capacity after that period.
Photo credits @ Daimler Truck
Safety features beyond the structure
Complementing the physical protection are several advanced driver assistance systems, including:
- Active Brake Assist 6 with 270° environmental monitoring, capable of autonomously stopping the truck if a collision risk is detected.
- Active Sideguard Assist 2 and Front Guard Assist, which help prevent side and frontal accidents involving pedestrians or cyclists.
- Active Drive Assist 3, supporting semi-automated highway driving.
- Attention Assist 2, warning drivers of inattention or fatigue.
To ensure vulnerable road users can hear the nearly silent truck, it also includes an Acoustic Vehicle Alerting System (AVAS) that emits a sound profile changing with speed and accelerator input, compliant with EU regulations for electric vehicles.
Why testing continues after launch
Photo credits @ Daimler Truck
Even though series production began at the Wörth plant in late 2024 and customer deliveries started in December, crash testing hasn’t stopped. Mercedes-Benz continues to conduct physical safety trials and feed real-world data from fleets into future updates.
This ongoing process is part of the manufacturer’s “Vision Zero” strategy, aimed at eliminating traffic fatalities involving its vehicles in the long term. Continuous testing also ensures compliance with evolving legislation and enables the integration of customer-driven design improvements.
Electric range, payload, and configuration
Photo credits @ Daimler Truck
The eActros 600, named for its battery capacity, achieves around 500 kilometres of range without intermediate charging when operating at a gross combination mass of 40 tonnes, under real-world long-haul conditions at 20°C. With intermediate charging during statutory driver breaks, the vehicle can exceed 1,000 kilometres per day.
Technically, the tractor unit supports up to 44 tonnes GCM, with a payload of around 22 tonnes in standard EU configuration. The model portfolio now includes over 40 vehicle variants, offering two or three battery packs, multiple wheelbases, and new axle configurations to suit different transport applications.
