Mercedes-Benz Trucks has presented the results of a real crash test with the battery-electric eActros 600. The test was conducted in Neumünster and was intended to assess the vehicle's passive safety under typical heavy-duty accident scenarios. According to the company, the high-voltage battery system of the electric truck remained undamaged even under strong impact.
Crash test confirms structural stability
In the test, the eActros 600 was subjected to a side impact as it can occur in severe traffic accidents. In the test, according to Mercedes-Benz Trucks, a mass of more than one ton moving at over 50 kilometers per hour collided with the truck from the side. Despite this force, the battery system remained intact. The result shows that the frame architecture developed for heavy-duty use and the reinforced cab dissipated the impact energy in a controlled manner.
The vehicle's safety concept includes defined energy absorption zones in the front end, which distribute the impact forces targeted through crash-optimized structures. In addition, airbags and seatbelt pretensioners are supposed to increase occupant protection in all model variants.
Safety concept for high-voltage system
The high-voltage system of the eActros 600 meets, according to the company, particularly high requirements for insulation, mechanical protection, and
fire-protection components to reduce potential risks after severe damage. These standards exceed legal requirements. After the test, a safety clearance was issued by specialized response personnel before a detailed damage analysis was conducted. It showed that there would have been no danger to drivers or rescue personnel.
Development based on real accident data
The internal accident research of Mercedes-Benz Trucks was involved from the outset in the development of the eActros 600. Real accident analyses were incorporated into the design to tailor safety measures to typical situations in heavy-duty transport. This approach is intended to ensure that occupant protection and the safety of the surrounding environment also meet high standards even with battery-electric drivetrains.
“Personally, the last two to three minutes before the crash are especially fascinating to me,” describes Christoph Berger from the Passive Safety team this moment shortly before the test sequence is triggered. “Everything becomes quieter than before, a focused tension is in the air.”
Continuous testing beyond series start
According to the company, Mercedes-Benz Trucks also conducts regular real-world crash tests even after the start of series production. The goal is to integrate new insights from field data and operations into ongoing vehicle development. In this way,
the manufacturer aims to ensure that technological developments can be implemented in a timely manner, that legal changes are met, and that new customer requirements are taken into account. The approach is part of the company's Vision Zero strategy, which aims to prevent accidents with serious injuries in the long term.
Active vehicle systems for greater safety
In addition to passive safety, the eActros 600 is equipped with a range of active assistance systems. These include, according to the manufacturer, Active Brake Assist 6 with 270-degree surround monitoring, Active Sideguard Assist 2 to assist with turning, Front Guard Assist to protect pedestrians and cyclists, and Active Drive Assist 3 for partially automated driving on highways. Attention Assist 2 warns of fatigue or inattention.
To ensure acoustic detectability in urban traffic, the eActros 600 features an external warning system. The so-called Acoustic Vehicle Alerting System generates different tones for forward and reverse driving depending on driving state, with volume and frequency adapting to speed and driving behavior.
Technical data and range
The eActros 600 has been delivered to customers since December 2024 and is currently in operation in more than 15 European countries. The vehicles are produced at the Wörth plant. According
to the company, the electric truck with a gross vehicle weight of 40 tons achieves a range of about 500 kilometers without intermediate charging under practical conditions, which can be significantly exceeded depending on route and driving style. This is made possible by three battery modules with a total capacity of 621 kilowatt-hours based on lithium iron phosphate cells.
The vehicle is designed for a combined gross vehicle weight of up to 44 tons and achieves a payload of about 22 tons with a standard trailer in the European Union. Between-charging during statutory breaks enables daily ranges of well over 1,000 kilometers, provided charging options are available.
Expanded model variants
Mercedes-Benz Trucks has expanded the portfolio of the eActros 600 with additional variants to cover different deployment requirements. The second generation comprises over 40 variants of the basic vehicle with different cabs, battery sizes, wheelbases, and axle configurations. All variants are based on the same electric drive axle and battery technology.
The eActros 600 was named Commercial Vehicle of the Year in 2025 by the organization “International Truck of the Year.” The basis for the award was the technical overall concept with an efficient drive axle and durable battery technology. (av)
