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 verify 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. During the test, according to Mercedes-Benz Trucks, a mass weighing more than one tonne collided laterally with the truck at over 50 kilometers per hour. Despite this force, the battery system remained intact. The result shows that the frame architecture developed for heavy-duty transport and the reinforced cab dissipated the impact energy in a controlled manner.
The safety concept of the vehicle includes defined energy-absorption zones in the front end that deliberately distribute the impact forces over crash-optimized structures. In addition, airbags and seatbelt pretensioners are intended to increase occupant protection in all model variants.
Safety concept for the high-voltage system
The high-voltage system of the eActros 600, according to the company, meets 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 responders before a detailed damage analysis was carried out. It showed that there would have been no danger to occupants 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 specifically 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 for battery-electric drives.
“What personally fascinates me most are the last two to three minutes before the crash,” describes Christoph Berger from the Passive Safety team this moment just before the test sequence is triggered. “Everything becomes quieter than before, a concentrated tension hangs in the air.”
Continued testing beyond production start
According to the company, Mercedes-Benz Trucks also conducts regular real accident tests even after the start of serial production. The aim is to incorporate new insights from field data and operations into the ongoing vehicle development. In this way, the
manufacturer intends to ensure that technological developments can be implemented promptly, that regulatory changes are complied with 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 severe injuries in the long term.
Active vehicle systems for greater safety
Alongside passive safety, the eActros 600 is equipped with a range of active assistance systems. These include, according to the manufacturer, the Active Brake Assist 6 with 270-degree surround monitoring, the Active Sideguard Assist 2 to assist with turning, the Front Guard Assist to protect pedestrians and cyclists, and the Active Drive Assist 3 for semi-automated driving on highways. The Attention Assist 2 warns of fatigue or inattention.
To ensure audible perception in urban traffic, the eActros 600 also features an external warning system. The so-called Acoustic Vehicle Alerting System generates different tones for forward and reverse driving depending on the driving state, with volume and frequency adapting to speed and driving behavior.
Technical data and operating 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 total weight of 40 tonnes achieves a range of about 500 kilometres without intermediate charging under realistic 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 total weight of up to 44 tonnes and achieves a payload of around 22 tonnes with a standard trailer in the European Union. Battery charging during statutory stops enables daily driving distances of well over 1,000 kilometres, provided that suitable 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 base vehicle with various 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 2025 by the organization "International Truck of the Year." The basis for the evaluation was the overall technical concept with an efficient drive axle and long-lasting battery technology.
