ZF LIFETEC Expands Michigan Facility with Next-Generation Crash Simulation and Safety Testing Capabilities

(left to right) ZF LIFETEC CEO Rudolf Stark, Head of Research and Development at ZF LIFETEC Harald Lutz, and ZF LIFETECs Senior Vice President of Inflatable Restraint Systems and Americas Passive Safety System Ned Reckamp cut the ribbon at
the grand opening of the new R&D and testing facility in Washington, MI, Macomb County Executive, Mark Hackel and Washington Township Supervisor, Sebastian Previti. Photo: ZF LIFETEC

(IN BRIEF) ZF LIFETEC has opened a cutting-edge technology and testing center in Washington, Michigan, enhancing its capacity to develop next-generation passive safety systems. The facility, which integrates prototype development, engineering, and testing operations, features a new servo-controlled sled system capable of replicating complex crash dynamics with precision. By consolidating its Romeo operations into the Washington site, ZF LIFETEC has created a centralized hub for research, design, and compliance with global safety standards. This investment underlines ZF’s long-term commitment to innovation, customer proximity, and the continued advancement of vehicle safety technologies worldwide.

(PRESS RELEASE) WASHINGTON, MI, Unites States/ ALFDORF, Germany, 7-Oct-2025 — /EuropaWire/ — ZF LIFETEC has officially inaugurated a state-of-the-art technology center in Washington, Michigan, strengthening its leadership in passive vehicle safety systems and innovation. The new facility marks a significant investment in modernizing and expanding the company’s North American operations, combining cutting-edge research, testing, and prototype development capabilities under one roof. The centerpiece of the new site is an advanced sled system capable of replicating a wide variety of crash scenarios, providing automotive manufacturers with a powerful tool for developing next-generation safety technologies.

“The new technology center is a symbol for customer proximity, technological excellence, and our ambition to develop the best solutions exactly where they are needed,” said Rudolf Stark, CEO of ZF LIFETEC. “By concentrating and enhancing our test equipment in this new building, we’re positioning ourselves for the future, strengthening collaboration with our partners, and improving response times for our customers. Supporting our customers locally remains our top priority.”

With its new Technology Center in Washington, MI, ZF LIFETEC is future-proofing its operations to meet upcoming NHTSA and NCAP safety standards. The centerpiece of the expanded facility is the new dynamic sled system.

The newly expanded 82,000-square-foot technology center—within a total site area of approximately 194,000 square feet—integrates prototype development, engineering, testing, and design functions. As part of the two-year modernization project, the company consolidated its Romeo site into the Washington facility, creating a unified hub for ZF’s passive safety innovations in North America.

“This new test center is a clear commitment to innovation and to our customers – and it’s a real competitive advantage,” said Ned Reckamp, Senior Vice President of Inflatable Restraint Systems and North America Passive Safety Systems. “This move boosts our efficiency and flexibility, enabling us to meet current and future NHTSA and NCAP requirements.”

Advancing Real-World Safety through Cutting-Edge Testing

The Washington site enables ZF LIFETEC to simulate complex crash dynamics that influence real-world occupant protection. Scenarios such as heavy braking before a frontal impact, oblique or offset collisions, rollovers, and height mismatches between vehicles can now be accurately replicated and analyzed. This level of precision supports the design and validation of adaptive restraint systems, which are increasingly critical in vehicles featuring advanced interior configurations and automated driving technologies.

The Technological Centerpiece: The New Sled System

At the heart of the new facility is a servo-controlled sled system with pitch-motion simulation, capable of generating 2.75 meganewtons of force—comparable to the thrust of an Airbus A380. This high-performance system allows engineers to reproduce vehicle motion during various crash events, enhancing the accuracy of testing for seatbelt dynamics, airbag deployment, and structural responses under realistic conditions.

Comprehensive Testing for Maximum Safety

ZF LIFETEC’s Washington site now offers an extensive range of testing and validation services, including component and full-system airbag tests, durability and functionality tests for airbags, seatbelts, and steering wheels, as well as environmental simulations covering temperature, humidity, vibration, and corrosion. The facility also features materials analysis labs and prototype development areas, creating a one-stop environment for innovation in passive safety.

Strengthening ZF LIFETEC’s Global Network

Originally established in 1987, the Washington site has played a key role in ZF LIFETEC’s legacy of safety innovation. The new expansion consolidates multiple departments—engineering, sales, program management, procurement, and testing—into a single, integrated campus. As part of ZF LIFETEC’s global network of over 51 locations in 22 countries, employing more than 36,000 people, this investment reinforces the company’s commitment to technological leadership and customer support in the North American market.

Press contacts:
Knut Zimmer, Spokesperson Product & Technology, ZF LIFETEC
Phone: +49 171 1506727, e-mail: knut.zimmer@zf-lifetec.com

About ZF LIFETEC
ZF LIFETEC is a leading passive safety technology provider for the enhanced protection of vehicle occupants. Employing more than 36,000 employees dedicated to the mission of saving lives with a technology driven approach, the company develops, manufactures and distributes a comprehensive product portfolio including airbag, seat belt and steering wheel systems, covering a wide range from small vehicles in the volume segment up to sophisticated luxury vehicles. Featuring a market share exceeding 20 percent in its core product categories, ZF LIFETEC has a worldwide presence at 51 locations across 22 countries. In the fiscal year 2024, the Group generated sales of EUR 4.8 billion. Based on its strong relationships with a diversified customer base of global OEMs, driven by outstanding quality, long-standing R&D collaborations besides a strong global innovation platform, ZF LIFETEC is well positioned for future growth opportunities arising from the automotive
megatrends electrification, (semi-) automated driving, smart interior, as well as increasing safety demands and stepped-up safety regulations worldwide. Learn more at www.zf-lifetec.com

SOURCE: ZF Group