With 52 critical crash investigations since 2019, including electric vehicle cases, Mercedes-Benz Research and Development India (MBRDI) combines high-tech tools like event data recorders, smart glasses, and 3D scanning with human expertise to transform fragmented crash data into actionable safety insights, shaping the future of vehicle safety.
23 Jan 2025 | 3539 Views | By Shahkar Abidi and Yukta Mudgal
On a foggy December night in 2022, the stillness of a North Indian highway was shattered by a fiery crash that could have ended in tragedy. Rishabh Pant, one of India’s most promising cricket stars, was driving alone in his Mercedes-Benz, traveling from Delhi to his hometown of Roorkee to ...
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On a foggy December night in 2022, the stillness of a North Indian highway was shattered by a fiery crash that could have ended in tragedy. Rishabh Pant, one of India’s most promising cricket stars, was driving alone in his Mercedes-Benz, traveling from Delhi to his hometown of Roorkee to surprise his mother for the New Year. About one kilometer before his destination, he succumbed to a moment of fatigue, dozing off at the wheel. What followed was a violent rollover that left his Mercedes-Benz engulfed in flames.
By some fate, Pant escaped. He broke a window, crawled out with cuts on his forehead, torn ligaments in his knee, and injuries to his wrist, back, and ankle. The incident left fans holding their breath for over a year while the young athlete underwent rehabilitation, eventually making his triumphant return to competitive cricket during the 2024 IPL.
But not all car crashes have such a redemptive arc.
Just a few months earlier, on a sunny afternoon in September 2022, another Mercedes-Benz—this time occupied by former Tata Sons chairman Cyrus Mistry—was speeding down the Ahmedabad-Mumbai highway. Mistry was seated in the back seat, alongside his friend JehangirPandole. AnahitaPandole, an accomplished gynecologist, was driving, with her husband, Darius, riding shotgun. Somewhere near Palghar, Anahita attempted an overtaking maneuver along the “hard shoulder,” a lane meant strictly for emergencies. In the heat of the moment, their car hit the road divider at speed. When the dust settled, Mistry and Jehangir were dead, while Anahita and her husband, Darius, sustained critical injuries.
A technical investigation team from Mercedes-Benz Research and Development India (MBRDI), also known as the “SWAT team,” arrived at the accident spots and meticulously examined both of these high-profile accidents to assist the police investigation, adhering to their standard practice of probing every crash involving their vehicles.
Manu Saale, Managing Director and CEO of Mercedes-Benz Research & Development India, said the company is able to reconstruct accidents with a precision of more than 80-85%, speaking on the sidelines of the Mercedes-Benz SAFE ROADS India Summit 2024 held recently in Bengaluru. The event is part of a nationwide SAFE ROADS initiative launched in 2015, bringing together policymakers, academia, industry, NGOs, and students, to foster dialogue and showcase innovative solutions for road safety.
In the case of cricketer Rishabh Pant, Saale's team concluded that "human error" was possibly the root cause of the accident. What ultimately saved Pant’s life, however, was a combination of factors: He had fastened his seatbelt, and the car’s protective cocoon absorbed the brunt of the impact. While the vehicle was consumed by flames, Mercedes-Benz’s safety systems, designed to function in such emergencies, performed as engineered, Saale pointed out.
However, the investigation into the tragic accident involving Cyrus Mistry painted a starkly different picture. The analysis of the car’s event data recorder (EDR) revealed that the vehicle was traveling at a speed of 100 km/hour just five seconds before the crash. The brakes were applied 3.5 seconds prior to the impact, reducing the speed to 89 km/hour at the moment of collision. Crucially, the driver, Dr. AnahitaPandole, reportedly failed to properly buckle her seatbelt and ensure that her co-passengers had done so as well, according to the investigation by police, inputs from MBRDI, and eyewitness accounts.
A Decade of Change: From Reporting to Reconstruction
On India’s intricate road network, where risk is a constant companion, luxury carmaker Mercedes Benz's accident research team—a unit dedicated to decoding the complex anatomy of crashes—is not just trying to reconstruct accidents; it reconstructs the very relationship between cars and their passengers, between risk and safety.
Reflecting on earlier years, Saale explained that around ten years ago, the role of MBRDI in accident analysis was rudimentary. It primarily involved collecting accident data from Indian roads and feeding it into global databases. While these efforts contributed to Mercedes-Benz’s safety systems worldwide, the Indian subsidiary realized it could go further. Just like their German counterparts, they could reconstruct accidents and analyze measurements from crash sites—and that’s when they saw an opportunity.
However, the institute’s work is not restricted to accident analysis. Established in 1996, MBRDI plays a prominent role in the development of technologies like connected, autonomous, and electric in the world of mobility. With offices in Bengaluru and Pune, MBRDI currently employs over 8,500 professionals engaged in digital product development, interior component design, IT engineering, and services.
Here, a team specialises in the granular art of accident reconstruction, the sensitive process of data anonymisation, and the meticulous analytics of accident databases. Their mission? To unravel the truth hidden in mangled steel and shattered glass using data to measure the effectiveness of safety systems under the uniquely demanding conditions of Indian roads. Since beginning active accident investigations in 2019, the team has delved into 52 critical cases, seven of which involved electric vehicles—a burgeoning sector with its own unique challenges. Among these was the first investigation of an EQS crash, a milestone that indicated the team’s dexterity in navigating the complexities of cutting-edge automotive technologies. By poring over accident data and mapping deformation patterns, they are not only identifying the vulnerabilities in existing safety measures but also laying the groundwork for tomorrow’s more resilient vehicles.
With an arsenal of cutting-edge tools, the Mercedes-Benz accident research team claims to be making efforts to push the boundaries of what it means to decode—and ultimately mitigate—road risks. At the heart of their operations lies a fusion of advanced technology and human ingenuity, where tools like Xentry diagnostics and Python-driven data analysis transform fragmented crash data into actionable safety insights. It’s a process as precise as it is urgent: a race to refine vehicle safety before the next collision occurs.
The toolkit is both high-tech and surprisingly tactile. Using 3D scanning with Scaniverse, the team captures the contours of crushed fenders and buckled steel in detail, rendering digital models that preserve every nuance of impact. VuZix smart glasses, meanwhile, bring augmented reality into the fray, enabling real-time global collaboration—an essential feature when safety innovation depends on the seamless sharing of expertise. Data flows in from e-Call systems embedded in vehicles, offering instant, precise accident tracking. But the team isn’t just crunching numbers; they’re safeguarding stories. Sophisticated anonymisation protocols ensure that behind every data point, privacy remains inviolable. “It’s like creating a CAD animation of what may have happened,” the top executive explained. "From there, we can look at everything—electronic inputs, crash site measurements, and even driver interviews—to piece together the story."
Accident reconstruction, company officials explained, has long been a staple of law enforcement, insurance inquiries, academia, and healthcare providers in Western nations. “I think we’re reaching that level of sophistication in India right now,” he noted. The same advanced methodologies used to unravel accidents on Europe’s autobahns and expressways are now being applied to India’s chaotic and unpredictable roads.
Learning from India’s Roads
India offers a tragic abundance of material for accident analysis and reconstruction. In 2023, an estimated 1.7 lakh people lost their lives on the country’s roads—a statistic that averages out to seven or eight deaths every minute. To grasp the enormity of this figure, consider the Airbus A380, the world’s largest passenger aircraft, capable of seating 853 people. It would take 200 fully loaded A380s to match this death toll, the equivalent of one such plane crashing every other day. Or, to put it another way, India loses the equivalent of Shimla’s entire population every year—a staggering, almost incomprehensible loss.
This learning process isn’t limited to internal research. Mercedes-Benz has also started engaging with Indian law enforcement and policymakers to share insights and explore ways to improve crash scene documentation. For instance, the company is exploring how tools like body cameras and AI-powered measurement software could help police officers document accident sites more effectively. “Imagine a police officer at a crash scene using a mobile device or camera to take measurements and digitally annotate everything,” Saale continued. "This technology isn’t a pipe dream—it’s within reach. And it could dramatically improve how accident data is collected in India."
Increased Need for Accident Reconstruction
Road accident reconstruction, according to experts, is an intricate and essential process—part science, part forensic art—that seeks to piece together the events surrounding a traffic collision. It examines the who, what, and why of an accident, peeling back its layers to reveal causes, consequences, and often unsettling truths. The process is critical to determining liability, be it the fault of the driver or the manufacturer, while also offering invaluable insights for improving road safety.
Using data extracted from Event Data Recorders (EDRs), accident reconstruction specialists retrace the precise choreography of a crash—calculating vehicle speeds, trajectories, and points of impact with almost mathematical precision. But the investigation doesn't stop there; in a country like India, where poorly marked lanes, uneven dividers, and ubiquitous potholes are all too common, road engineering flaws also find their way into the narrative of culpability.
The implications of this work extend far beyond the courtroom. By analyzing the mechanics of collisions—the crumpled steel, the shattered glass, the haunting angles of crushed vehicles—reconstruction experts uncover patterns that inform preventative measures, offering pathways to avert future tragedies. This is not merely a backward glance at what went wrong; it’s a forward-looking effort to predict and mitigate road risks.
The work also feeds into the evolving technology of accident modeling. Data from collision sites—positions of vehicles, their orientation at the moment of impact—helps experts develop predictive models capable of estimating speeds and damage under similar conditions. These simulations are not just academic exercises; they form the basis for innovations in emergency response systems, ensuring quicker reaction times and improved services along high-risk highways. In the hands of these investigators, accidents become blueprints for safety, offering, if not solace, then at least a semblance of progress.
On a foggy December night in 2022, the stillness of a North Indian highway was shattered by a fiery crash that could have ended in tragedy. Rishabh Pant, one of India’s most promising cricket stars, was driving alone in his Mercedes-Benz, traveling from Delhi to his hometown of Roorkee to surprise his mother for the New Year. About one kilometer before his destination, he succumbed to a moment of fatigue, dozing off at the wheel. What followed was a violent rollover that left his Mercedes-Benz engulfed in flames.
By some fate, Pant escaped. He broke a window, crawled out with cuts on his forehead, torn ligaments in his knee, and injuries to his wrist, back, and ankle. The incident left fans holding their breath for over a year while the young athlete underwent rehabilitation, eventually making his triumphant return to competitive cricket during the 2024 IPL.
But not all car crashes have such a redemptive arc.
Just a few months earlier, on a sunny afternoon in September 2022, another Mercedes-Benz—this time occupied by former Tata Sons chairman Cyrus Mistry—was speeding down the Ahmedabad-Mumbai highway. Mistry was seated in the back seat, alongside his friend JehangirPandole. AnahitaPandole, an accomplished gynecologist, was driving, with her husband, Darius, riding shotgun. Somewhere near Palghar, Anahita attempted an overtaking maneuver along the “hard shoulder,” a lane meant strictly for emergencies. In the heat of the moment, their car hit the road divider at speed. When the dust settled, Mistry and Jehangir were dead, while Anahita and her husband, Darius, sustained critical injuries.
A technical investigation team from Mercedes-Benz Research and Development India (MBRDI), also known as the “SWAT team,” arrived at the accident spots and meticulously examined both of these high-profile accidents to assist the police investigation, adhering to their standard practice of probing every crash involving their vehicles.
Manu Saale, Managing Director and CEO of Mercedes-Benz Research & Development India, said the company is able to reconstruct accidents with a precision of more than 80-85%, speaking on the sidelines of the Mercedes-Benz SAFE ROADS India Summit 2024 held recently in Bengaluru. The event is part of a nationwide SAFE ROADS initiative launched in 2015, bringing together policymakers, academia, industry, NGOs, and students, to foster dialogue and showcase innovative solutions for road safety.
In the case of cricketer Rishabh Pant, Saale's team concluded that "human error" was possibly the root cause of the accident. What ultimately saved Pant’s life, however, was a combination of factors: He had fastened his seatbelt, and the car’s protective cocoon absorbed the brunt of the impact. While the vehicle was consumed by flames, Mercedes-Benz’s safety systems, designed to function in such emergencies, performed as engineered, Saale pointed out.
However, the investigation into the tragic accident involving Cyrus Mistry painted a starkly different picture. The analysis of the car’s event data recorder (EDR) revealed that the vehicle was traveling at a speed of 100 km/hour just five seconds before the crash. The brakes were applied 3.5 seconds prior to the impact, reducing the speed to 89 km/hour at the moment of collision. Crucially, the driver, Dr. AnahitaPandole, reportedly failed to properly buckle her seatbelt and ensure that her co-passengers had done so as well, according to the investigation by police, inputs from MBRDI, and eyewitness accounts.
A Decade of Change: From Reporting to Reconstruction
On India’s intricate road network, where risk is a constant companion, luxury carmaker Mercedes Benz's accident research team—a unit dedicated to decoding the complex anatomy of crashes—is not just trying to reconstruct accidents; it reconstructs the very relationship between cars and their passengers, between risk and safety.
Reflecting on earlier years, Saale explained that around ten years ago, the role of MBRDI in accident analysis was rudimentary. It primarily involved collecting accident data from Indian roads and feeding it into global databases. While these efforts contributed to Mercedes-Benz’s safety systems worldwide, the Indian subsidiary realized it could go further. Just like their German counterparts, they could reconstruct accidents and analyze measurements from crash sites—and that’s when they saw an opportunity.
However, the institute’s work is not restricted to accident analysis. Established in 1996, MBRDI plays a prominent role in the development of technologies like connected, autonomous, and electric in the world of mobility. With offices in Bengaluru and Pune, MBRDI currently employs over 8,500 professionals engaged in digital product development, interior component design, IT engineering, and services.
Here, a team specialises in the granular art of accident reconstruction, the sensitive process of data anonymisation, and the meticulous analytics of accident databases. Their mission? To unravel the truth hidden in mangled steel and shattered glass using data to measure the effectiveness of safety systems under the uniquely demanding conditions of Indian roads. Since beginning active accident investigations in 2019, the team has delved into 52 critical cases, seven of which involved electric vehicles—a burgeoning sector with its own unique challenges. Among these was the first investigation of an EQS crash, a milestone that indicated the team’s dexterity in navigating the complexities of cutting-edge automotive technologies. By poring over accident data and mapping deformation patterns, they are not only identifying the vulnerabilities in existing safety measures but also laying the groundwork for tomorrow’s more resilient vehicles.
With an arsenal of cutting-edge tools, the Mercedes-Benz accident research team claims to be making efforts to push the boundaries of what it means to decode—and ultimately mitigate—road risks. At the heart of their operations lies a fusion of advanced technology and human ingenuity, where tools like Xentry diagnostics and Python-driven data analysis transform fragmented crash data into actionable safety insights. It’s a process as precise as it is urgent: a race to refine vehicle safety before the next collision occurs.
The toolkit is both high-tech and surprisingly tactile. Using 3D scanning with Scaniverse, the team captures the contours of crushed fenders and buckled steel in detail, rendering digital models that preserve every nuance of impact. VuZix smart glasses, meanwhile, bring augmented reality into the fray, enabling real-time global collaboration—an essential feature when safety innovation depends on the seamless sharing of expertise. Data flows in from e-Call systems embedded in vehicles, offering instant, precise accident tracking. But the team isn’t just crunching numbers; they’re safeguarding stories. Sophisticated anonymisation protocols ensure that behind every data point, privacy remains inviolable. “It’s like creating a CAD animation of what may have happened,” the top executive explained. "From there, we can look at everything—electronic inputs, crash site measurements, and even driver interviews—to piece together the story."
Accident reconstruction, company officials explained, has long been a staple of law enforcement, insurance inquiries, academia, and healthcare providers in Western nations. “I think we’re reaching that level of sophistication in India right now,” he noted. The same advanced methodologies used to unravel accidents on Europe’s autobahns and expressways are now being applied to India’s chaotic and unpredictable roads.
Learning from India’s Roads
India offers a tragic abundance of material for accident analysis and reconstruction. In 2023, an estimated 1.7 lakh people lost their lives on the country’s roads—a statistic that averages out to seven or eight deaths every minute. To grasp the enormity of this figure, consider the Airbus A380, the world’s largest passenger aircraft, capable of seating 853 people. It would take 200 fully loaded A380s to match this death toll, the equivalent of one such plane crashing every other day. Or, to put it another way, India loses the equivalent of Shimla’s entire population every year—a staggering, almost incomprehensible loss.
This learning process isn’t limited to internal research. Mercedes-Benz has also started engaging with Indian law enforcement and policymakers to share insights and explore ways to improve crash scene documentation. For instance, the company is exploring how tools like body cameras and AI-powered measurement software could help police officers document accident sites more effectively. “Imagine a police officer at a crash scene using a mobile device or camera to take measurements and digitally annotate everything,” Saale continued. "This technology isn’t a pipe dream—it’s within reach. And it could dramatically improve how accident data is collected in India."
Increased Need for Accident Reconstruction
Road accident reconstruction, according to experts, is an intricate and essential process—part science, part forensic art—that seeks to piece together the events surrounding a traffic collision. It examines the who, what, and why of an accident, peeling back its layers to reveal causes, consequences, and often unsettling truths. The process is critical to determining liability, be it the fault of the driver or the manufacturer, while also offering invaluable insights for improving road safety.
Using data extracted from Event Data Recorders (EDRs), accident reconstruction specialists retrace the precise choreography of a crash—calculating vehicle speeds, trajectories, and points of impact with almost mathematical precision. But the investigation doesn't stop there; in a country like India, where poorly marked lanes, uneven dividers, and ubiquitous potholes are all too common, road engineering flaws also find their way into the narrative of culpability.
The implications of this work extend far beyond the courtroom. By analyzing the mechanics of collisions—the crumpled steel, the shattered glass, the haunting angles of crushed vehicles—reconstruction experts uncover patterns that inform preventative measures, offering pathways to avert future tragedies. This is not merely a backward glance at what went wrong; it’s a forward-looking effort to predict and mitigate road risks.
The work also feeds into the evolving technology of accident modeling. Data from collision sites—positions of vehicles, their orientation at the moment of impact—helps experts develop predictive models capable of estimating speeds and damage under similar conditions. These simulations are not just academic exercises; they form the basis for innovations in emergency response systems, ensuring quicker reaction times and improved services along high-risk highways. In the hands of these investigators, accidents become blueprints for safety, offering, if not solace, then at least a semblance of progress.
Crash Investigation Has Come a Long Way
Over the past decade, the field of crash analysis and reconstruction has undergone a remarkable transformation, as noted by Manu Saale. A decade ago, the tools of the trade were rudimentary at best: measurements were taken manually, and reconstructions bore a crude quality, offering little more than abstract approximations of real-life accidents. The technology was imprecise, prone to error, and incapable of providing the detailed insights demanded by an ever-complex automotive world.
Today, however, crash reconstruction is an entirely different beast. Auto-measurements have reached a level of precision that allows for reconstructions rendered in stunningly lifelike 3D animations, a leap that has not only refined accuracy but also deepened the understanding of crashes for stakeholders ranging from manufacturers to policymakers. This shift, Saale pointed out, has elevated accident analysis from a forensic exercise to an essential tool in shaping the future of vehicle safety.
Among the milestones in this digital evolution is the newfound ability to scrutinize crumple zones, a critical feature of modern vehicle design intended to absorb the force of impact during collisions. With today’s advanced modeling, analysts can study the performance of these zones under varying conditions—whether a crash involves a 25% overlap, a 50% overlap, or a catastrophic head-on collision. These digital tools offer granular insights into how crumple zones perform in extreme scenarios, such as drunk driving incidents or high-speed frontal crashes, providing manufacturers with the data necessary to refine designs and improve real-world safety outcomes.
Perhaps most impressive is how seamlessly this new technology integrates real crash data with the computer-aided engineering (CAE) simulations originally used during the vehicle design process. This fusion allows Original Equipment Manufacturers (OEMs) to compare a vehicle’s design intent with its performance in actual accidents, bridging the gap between theoretical safety and the often-chaotic reality of the open road. The result is a safer, smarter future—crafted, as it turns out, in painstaking detail. In fact, the data now collected in India is also being used in other countries for improving vehicles and other essentialities.
Prof. Dr. Paul Dick, Director of Vehicle Safety, Durability, Corrosion Protection, Mercedes-Benz AG. remarked: "Road safety is a global challenge that demands localized understanding and actionable solutions. MBRDI's decade-long accident research provides crucial insights in fulfilling this purpose."
Bridging the Gap Between Innovation and Impact
For all the advancements in vehicle safety and accident reconstruction, India’s staggering annual road fatality figures are a sobering reminder of how far there is to go. The gulf between innovation and impact remains wide, demanding a multifaceted approach that extends beyond technology. Greater enforcement of traffic laws, a cultural shift in road safety education, and sustained partnerships between NGOs, policymakers, and automakers are imperative. Companies like Mercedes-Benz have already taken steps, using data to emphasize the lifesaving potential of seat belts. Their study in India found that 95 percent of drivers and front passengers wearing seat belts escaped injury, a statistic that underlines the quiet but profound power of passive safety systems. Bridging the gap between innovation and behavioral change may not be as seamless as reconstructing a crash in lifelike 3D, but the stakes—thousands of lives each year—demand nothing less than tireless collective resolve.
Over the past decade, the field of crash analysis and reconstruction has undergone a remarkable transformation, as noted by Manu Saale. A decade ago, the tools of the trade were rudimentary at best: measurements were taken manually, and reconstructions bore a crude quality, offering little more than abstract approximations of real-life accidents. The technology was imprecise, prone to error, and incapable of providing the detailed insights demanded by an ever-complex automotive world.
Today, however, crash reconstruction is an entirely different beast. Auto-measurements have reached a level of precision that allows for reconstructions rendered in stunningly lifelike 3D animations, a leap that has not only refined accuracy but also deepened the understanding of crashes for stakeholders ranging from manufacturers to policymakers. This shift, Saale pointed out, has elevated accident analysis from a forensic exercise to an essential tool in shaping the future of vehicle safety.
Among the milestones in this digital evolution is the newfound ability to scrutinize crumple zones, a critical feature of modern vehicle design intended to absorb the force of impact during collisions. With today’s advanced modeling, analysts can study the performance of these zones under varying conditions—whether a crash involves a 25% overlap, a 50% overlap, or a catastrophic head-on collision. These digital tools offer granular insights into how crumple zones perform in extreme scenarios, such as drunk driving incidents or high-speed frontal crashes, providing manufacturers with the data necessary to refine designs and improve real-world safety outcomes.
Perhaps most impressive is how seamlessly this new technology integrates real crash data with the computer-aided engineering (CAE) simulations originally used during the vehicle design process. This fusion allows Original Equipment Manufacturers (OEMs) to compare a vehicle’s design intent with its performance in actual accidents, bridging the gap between theoretical safety and the often-chaotic reality of the open road. The result is a safer, smarter future—crafted, as it turns out, in painstaking detail. In fact, the data now collected in India is also being used in other countries for improving vehicles and other essentialities.
Prof. Dr. Paul Dick, Director of Vehicle Safety, Durability, Corrosion Protection, Mercedes-Benz AG. remarked: "Road safety is a global challenge that demands localized understanding and actionable solutions. MBRDI's decade-long accident research provides crucial insights in fulfilling this purpose."
Bridging the Gap Between Innovation and Impact
For all the advancements in vehicle safety and accident reconstruction, India’s staggering annual road fatality figures are a sobering reminder of how far there is to go. The gulf between innovation and impact remains wide, demanding a multifaceted approach that extends beyond technology. Greater enforcement of traffic laws, a cultural shift in road safety education, and sustained partnerships between NGOs, policymakers, and automakers are imperative. Companies like Mercedes-Benz have already taken steps, using data to emphasize the lifesaving potential of seat belts. Their study in India found that 95 percent of drivers and front passengers wearing seat belts escaped injury, a statistic that underlines the quiet but profound power of passive safety systems. Bridging the gap between innovation and behavioral change may not be as seamless as reconstructing a crash in lifelike 3D, but the stakes—thousands of lives each year—demand nothing less than tireless collective resolve.