GMW 3112-2012

WORLDWIDE
ENGINEERING General Specification GMW3112

STANDARDS
Verification of Requirements for Frontal Airbag Modules
1 Introduction 3
1.1 Scope 3
1.2 Mission/Theme 3
1.3 Classification 3
2 References 3
2.1 External Standards/Specifications 3
2.2 GM Standards/Specifications 3
2.3 Additional References 4
3 Requirements 4
3.1 System/Subsystem/Component/Part Definition 4
3.2 Product Characteristics 4

3.2.1 Performance Requirements 4
3.2.1.1 Static Deployment Test 4
3.2.1.2 DAB/PAB/KAB Module Sequential/Environmental Test 12
3.2.1.3 Heat Aging 18
3.2.1.4 Conformité Européene (CE) Conformity Pyrotechnic Directive 2007/23/EC 20
3.2.1.5 Module Drop Test 20
3.2.1.6 Module Effluent Test 20
3.2.1.7 Solar Exposure Test 21
3.2.1.8 Ozone Exposure Test 21
3.2.1.9 Module Electrical Stress Test 22
3.2.1.10 Module Fatigue Resistance Test 22
3.2.1.11 Horn Tests 23
3.2.1.12 Module Hand Impact Resistance Test 23
3.2.1.13 Module and Door/Cover Finger Indentation Resistance Test 24
3.2.1.14 PAB/KAB Module Pry Resistance Test 25
3.2.1.15 Module Integrity Test DAB/PAB/KAB 26
3.2.1.16 Out-Of-Position Body Block Test for Low Risk Deployment PAB 28
3.2.1.17 DAB Module Emblem Deformation Resistance Test 29
3.2.1.18 Push-in/Snap-in Attachment Insertion Effort Procedure 31
4 Validation 31
4.1 General 31
4.1.1 Inspection and Preparation 31
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© Copyright 2012 General Motors Company All Rights Reserved
December 2012 Originating Department: GME Specification Center Page 1 of 49
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Copyright GM Worldwide
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No reproduction or networking permitted without license from IHS
GM WORLDWIDE ENGINEERING STANDARDS GMW3112
4.2 Validation Plan 31

4.2.1 Design Validation (DV) Requirements 32
4.2.1.1 Module Design Validation Test Matrix 33
4.2.1.2 PAB and KAB System Level DV Test Matrix 37
4.2.2 Product Process Validation (PV) Requirements 38
4.2.2.1 Module Process Validation Test Matrix 38
4.2.2.2 PAB and KAB System Level PV Test Matrix 41
4.2.3 Dual Depth Mechanism/Active Vent Subcomponent Validation Requirements 41
4.2.3.1 Dual Depth Mechanism/Active vent Subcomponent DV Test Matrix 42
4.2.3.2 Dual Depth Mechanism/Active vent PV Subcomponent Test Matrix 43
4.3 Supporting Paragraphs 43
4.3.1 Product Audit Requirements 43
5 Provisions for Shipping 44
6 Notes 44
6.1 Glossary 44
6.2 Acronyms, Abbreviations, and Symbols 44 --```,``,`,,,`,``````,,-`-`,,`,,`,`,,`---
7 Additional Paragraphs 45
8 Coding System 45
9 Release and Revisions 45
Appendix A 47
A1 Module Post Test Documentation 47
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December 2012 Page 2 of 49
1 Introduction
Note: Nothing in this standard supercedes applicable laws and regulations.
Note: In the event of conflict between the English and domestic language, the English language shall take
precedence.
1.1 Scope. This standard sets forth the validation procedures and associated performance requirements for
Driver, Passenger or Knee Airbag Module assemblies (hereinafter referred to as the Module) that will be used
for frontal airbag systems in GM vehicles. This document does not address developmental test requirements. It
shall be the responsibility of the supplier to identify and conduct a Development and Concept Validation Test
Plan as defined in the program Statement of Requirements, and/or the Design Failure Mode and Effects
Analysis (DFMEA)/ Process Failure Mode and Effects Analysis (PFMEA). Module Development Testing shall
be completed prior to start of Design Validation (DV) Testing.
The Module Validation Test Plans shall be structured in accordance to the DV and Process/Production
Validation (PV) Test Matrixes (paragraphs 4.2.1.1, 4.2.1.2, 4.2.2.1 and 4.2.2.2) in this document. The Dual
Depth/Active Vent Mechanism (if present) Subcomponent Validation Test Plans shall be structured in
accordance to the DV and PV Test Matrixes (paragraphs 4.2.3.1 and 4.2.3.2) in this document. These
requirements shall contain but not be limited to a minimum set of tests and sample sizes for validating
Modules. It shall be the supplier’s responsibility to evaluate the plans and determine if additional testing and/or
larger sample sizes are recommended based on the supplier’s developed DFMEA and PFMEAs. The Module
Development, DV, and PV Test Plans shall be approved by the responsible Vehicle Engineering Center (VEC)
Engineer prior to implementation. In addition to this specification, module shall meet inflator (USCAR-24),
Initiator (USCAR-28) and cover material specifications (GMW3133 and GMW14444).
The validation test set up and test procedure shall be approved by the responsible Vehicle Engineering Center
(VEC) Engineer prior to implementation. If requirements stated herein are not objectively defined, the
responsible VEC shall be the final arbiter of these requirements.
1.2 Mission/Theme. The Modules are intended to supplement the restraint offered by the seat belt systems for
frontal collisions. The objective of the Frontal Airbag System is to deploy the Module's cushion and potentially
mitigate interior contacts in case of a frontal collision if a specified deceleration characteristic (collision pulse)
during the crash of a vehicle is exceeded. The Module is intended to reduce injury potential in those frontal
accidents where there is a significant risk that drivers might otherwise be seriously injured, meet applicable
regulations, and address GM Worldwide (GMW) performance goals.
1.3 Classification.
Driver Airbag Module (DAB)
Passenger Airbag Module (PAB)
Knee Airbag Module (KAB), which may be either Driver Knee Airbag Module (DKAB) or Passenger Knee
Airbag Module (PKAB)
The stages for a dual level Modules are defined as follows:
High Level: Module high level performance is the maximum performance level that the module is capable of.
Low Level: Module low level is the reduced performance increment below high level performance.
Note: The responsible VEC will define in detail high level and low level Module performance on a program and
Module technology specific basis.
2 References
Note: Only the latest approved standards are applicable unless otherwise specified.
2.1 External Standards/Specifications.
2007/23/EC IEC 60068-2-27 ISO 1431-1 USCAR-28

FMVSS 208 IEC 60068-2-38 SAE J1794
IEC 60068-2-14 IEC 60068-2-64 USCAR-24
2.2 GM Standards/Specifications.
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GMW3059 GMW3133 GMW14011 GMW14444
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GMW3097GMW3286 GMW14096 GMW14595

GMW3109GMW3417 GMW14162 GMW14599
2.3 Additional References.
Department of Transportation (DOT), test procedures
Program Specific Statement of Requirements (SOR)
GM Evaluation Considerations Book
CG3378 Airbag Lot acceptance test matrix
3 Requirements
The use of “shall” in this document denotes a binding provision that must be met unless a deviation is granted
by the responsible VEC. Deviations to shall requirements will only be considered and, if approved, granted by
the responsible VEC after evaluating appropriate available technologies and balancing all Module and restraint
system performance considerations.
“Should” denotes a preference, or desired conformance that must be tested and, if not met, must be
documented and disclosed by the Supplier and approved by the responsible VEC. Should requirements must
be met unless non-compliance has been approved by the responsible VEC.
The term “Airbag” refers to the airbag subsystem with design intent wire harness, labels, and non specific
components (e.g. the cushion).
Test Equipment shall be utilized as specified, by the indicated test procedures, standards and specifications.
Test Equipment. Unless otherwise specified elsewhere in this document, tests shall be conducted at local
ambient pressure, relative humidity, and room temperature (+23 ± 3) °C.
Unless otherwise specified in this document, test condition tolerances shall be as stated in Table 1:
Table 1: Test Condition Tolerances
Temperature ± 3 °C
Relative Humidity (RH) ± 5 % of RH

Vacuums ± 10 mm of Hg
Height ± 0.05 m
Acceleration ± 2 % except where minimums are stated
Frequency ± 4 % or ± 2 Hz, whichever is smaller

Current ± 0.01 A
Voltage (in V) ±5%
Resistance (in ) ± 1.0 %
Angle ± 1.0°
All test conditions shall be within the above stated tolerances at the time of test. These tolerances shall not be
used independently.
Test Samples. Test sample size requirements according to paragraphs 4.2.1, 4.2.2 and 4.2.3.
3.1 System/Subsystem/Component/Part Definition. Not applicable.
3.2 Product Characteristics.
3.2.1 Performance Requirements. Refer to paragraph 4.2 for the number of test samples to use in each test.
3.2.1.1 Static Deployment Test.
3.2.1.1.1 PAB/ KAB Module Static Deployment Test.
Note: DAB module is considered system level see paragraph 3.2.1.1.2, “DAB/PAB/KAB System Static Deployment test”.
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Purpose: To evaluate the Module performance structural integrity.

Test Fixtures and Equipment.
Conditioning chamber, capable of holding (-30 to +85) °C.
Heating blanket, capable of heating the cover/door surface up to +110 °C in 60 s.
Rigid fixture that represent in-vehicle Module orientation and mounting system.
Module mounting shall simulate vehicle environment, including reaction surfaces when applicable.
Module Cover and/or surrogate door (if required).

Actuation device that also switches on the measuring equipment.
Approved Data Acquisition System.
Test backdrop with grid.
Prior to Module DV assembly build, the cushion vents and tether attachments should be marked with a
vertical and horizontal reference line, for visibility during deployment.
High speed cameras (3000 frames/s minimum for tear seam opening, all others can be 1000 frames/s).
A minimum of three cameras is required. For PAB modules containing any feature for modifying or
directing deployment energy for out-of-position occupants, additional camera views may be required at the
discretion of the responsible VEC to view and evaluate this feature. Each camera shall have a lens, which
allows a full view of the Module and inflated cushion.
Lights (High intensity to enable viewing of all components).

Industrial Fan to cool windshield ( 1 meter diameter)
Thermocouples that can measure temperatures up to +110 °C.
Strobe Light (to indicate T=0).
ID-labels (with test number).
Data Required.
Conditioning temperature and ambient temperature in test cell during the test.
Voltage and current vs. time.
High speed videos.
Test Procedure.
a. Set up and adjust high speed cameras to allow a full view of the Module and inflated cushion Initial frames
to include title block with test number, program ID, test date.
b. Set up lights in a manner that provides sufficient lighting for all camera views but does not wash out
cushion image
c. Set up strobe light to illuminate Module, to show T = 0 on all high-speed cameras.
d. Document test date, sample number and serial number. Attach ID label to front and side of the test
fixture/steering wheel/instrument panel (IP).
e. Take still photographs of Module before test.
f. Measure and record Module electrical resistance, insulation resistance, and shunt resistance as follows:
1. Measure the terminal-to-terminal resistance. The resistance in terminal-to-terminal test mode shall be
(2.0 ± 0.3) .
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2. Measure the resistance in shorted terminal-to-inflator-case. The resistance in shorted terminal-to-

inflator-case (insulation resistance) shall be ≥ 1.0 MΩ when subjected to 500 V Direct Current (VDC)
for 2 s.
3. If applicable, measure the shorting clip resistance (shunt resistance) terminal-to-terminal. The
shorting clip resistance terminal-to-terminal with shunt bar in position shall be ≤150 mΩ .
Note: Shunt resistance measurement “if applicable” applies to all shunt resistance paragraphs.
g. Mount Module in the rigid fixture/steering wheel/IP/Knee Bolster. Module mounting shall simulate vehicle
environment, including reaction surfaces when applicable.
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h. Install thermocouples to measure the following Module Subcomponents

1. Module Housing Assembly (for verification of Module Temperature at Deployment)
2. Module PAB/KAB Door Assembly (for verification of Door Surface Temperature at Deployment)
3. Module DAB Door Assembly (For verification of Door Surface Temperature at Deployment)
i. Place the above fixture with the Module in the conditioning chamber and condition them at -30, or +23, or
+85 °C. The duration of Module conditioning shall be such that the core temperature of the Inflator within
the Module reaches and maintains the required conditioning temperature unless otherwise indicated. The
Supplier shall provide data to the responsible VEC Engineer, indicating the time duration (t e) required for
the Inflator’s core temperature within the Module assembly to reach and maintain the specified
conditioning temperature. The method and Module quantity (Module quantity shall represent quantities
used for DV/PV testing) used to demonstrate Inflator core temperature shall be reviewed and approved
with the responsible VEC prior to testing and after approval test duration can be modified to
(te) + 30 minutes If the time duration (te) data is not provided, the minimum time for Module conditioning is
4 h.This statement applies to all temperature conditioning.
j. Activate the data acquisition system. The following data shall be recorded:
4. Current plot.
5. Test temperatures
k. Activate the high speed cameras or videos.
l. Actuate each Module with the minimum actuation current (1.2 A) at the corresponding conditioning
temperature. The Module shall be deployed at 2 minutes (± 5 s), after Module removal from conditioning
chamber.
m. Dual stage modules shall be activated with a 0 ms delay between first and second stages for DV module
level tests and program specific delay for PV module level tests (if not specified use 5 ms for PV).
n. Take still photographs of Module, Cover/Door, Cushion Assembly and Module Housing after test, including
detailed close up photographs of any possible non conformance to the performance requirements of
GMW3109.
o. Test facility to complete post test documentation and retain indefinitely; see Appendix A
Evaluation and Results. Module shall meet the functional requirements stated in GMW3109. Any feature for
modifying or directing deployment energy for out-of-position occupants shall exhibit intended functionality in
video coverage recorded during the test. If intended functionality cannot be evaluated in video coverage, the
responsible VEC may specify additional tests to evaluate module performance. Module traceability bar code
and label legibility shall meet the requirements stated in GMW3109 paragraph “Label legibility”.
3.2.1.1.2 DAB/ PAB/KAB System Static Deployment Test.
Purpose. To evaluate DAB/PAB/KAB system performance and structural integrity.
a. Conditioning chamber, capable of holding (-30 to +85) °C.
b. Heating blanket, capable of heating the cover/door surface up to +110 °C (see Figure 1)
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Figure 1: Heating Blanket
Piece of cardboard placed on top of heating blanket to keep from radiating up onto windshield (the thicker the
cardboard piece the better).
c. Vehicle front Body In White (B-I-W) (from front of dashboard to B pillar) that represent in-vehicle Module
orientation and mounting system.
d. Module mounting shall simulate vehicle environment, Steering wheel and column shaft, built up IP
including reaction surfaces when applicable (roof trim, sun visors, A pillar trim, rear view mirror, windshield,
IP, hush panel, console).
e. Cover and/or door required.
f. PAB: Vehicle windshield is required if deployment door or cushion contacts windshield during deployment.
If deployment door or cushion does not contact windshield, alternative windshield material (i.e. Plexiglas,
Lexan) may be used.
g. Actuation device that also switches on the measuring equipment.
h. Approved Data Acquisition System.
i. Test backdrop with grid to help evaluate cushion kinematics.
j. Prior to Module DV assembly build, the cushion vents and tether attachments should be marked with a
vertical and horizontal reference line, for visibility during deployment.
k. High speed cameras (3000 frames/s minimum for tear seam opening, all others can be
1000 frames/s minimum). A minimum of five (5) cameras/videos required for PAB/KAB testing, minimum of
three for PAB only, minimum of two for DAB/KAB only. For airbags containing any feature for modifying or
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directing deployment energy for out-of-position occupants, additional camera views may be required at the
discretion of the responsible VEC to view and evaluate this feature. Each camera shall have a lens, which
allows a full view of the Module and inflated cushion.
l. Lights (High intensity to enable viewing of all components).
m. Thermocouples that can measure temperatures up to +110 °C.
n. Strobe Light (to indicate T=0).
o. ID-labels (with test number).
p. Large diameter cooling fan ( ≈1 meter diameter). Position Fan at Centerline of PAB door assembly (see
Figure 2)
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Figure 2: Fan Position
1 Fan positioned on centerline of airbag door opening.
q. Thermocouple: --```,``,`,,,`,``````,,-`-`,,`,,`,`,,`---
Type K 24 gauge wire, 508 teflon wrap: K24-2-508 Temprel
Tig welded thermal couple junction for surface temperature recordings

For plastic surface – melted into surface w/soldering iron/gun
For fabric material – pierced hole & inserted into/onto surface, held in place with 3M silver tape core
series 292-7
For glass surface – clear package/scotch tape covered entire welded junction
Thermocouple Attachments for PAB/KAB: (see Figures 3 thru 4)
One - On the PAB/KAB housing at centerline of occupant.

One - On the IP PAB/KAB deployment door (locate at the geometric center of door, without interfering
with the tear seam).
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One on the Passenger side windshield inner, located at about a mid height biased to the passenger
side of centerline of vehicle but not in the deployment path of the airbag
Figure 3: Thermocouple Position on I/P
1 Locate at the geometric center of door, without interfering with the tear seam or hinge and does not make
contact with windshield
Figure 4: Thermocouple Position on Windshield
1 Thermocouple location on windshield ≈ 30 mm above projected contact and ≈ 75 mm inboard. Not

interfering with cushion.
2 Projected door contact on windshield.
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One - Within chamber to record temperature.

Thermocouple attachment for DAB (see Figure 5).
Figure 5: Thermocouple Position on DAB
1 Thermocouple location on DAB cover – top/horizontal surface, mid cross-car, forward in car of any tear
Seam
Data Required.
Conditioning temperature and ambient temperature in test cell during the test.
Voltage and current vs. time.
High speed videos
Pre and Post test Photographs
3.2.1.1.2.1 PAB/KAB System Static Deployment Test – Hot.

Test Procedure.
a. Condition PAB/KAB System at +75 °C.
b. Actuate heating blanket, ≈ 5 minutes prior to deployment, to stabilize deployment door/top pad to the soak
temperature given in Table 2 (stabilize temperature means to maintain temperature for 5 minutes)
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c. PAB only (if PAB deployment door or cushion interacts with windshield): Upon completion of heating
blanket soak, turn on fan to highest setting to cool windshield, open the chamber (or remove buck from
chamber), use heating blanket to maintain deployment door/top pad temperature, ensure adhesion of
thermocouple on windshield by pressing on the tape holding thermocouple and monitor windshield
thermocouple to reach deployment temperature given in Table 2.
d. Remove heating blanket.
e. Monitor I/P thermocouple while confirming windshield temperature to be within deployment temperature in
Table 2. Deploy Module when the deployment door/top pad reaches the deployment temperature given in
Table 2. Dual stage modules shall be activated with a 0ms delay between first and second stages for DV
and a program specific delay for PV (if not defined use 5 ms for PV). Test Facility to complete and retain
post test documentation indefinitely; see Appendix A.
3.2.1.1.2.2 DAB System Deployment Test – Hot.
a. Condition DAB module and Steering wheel at +85 °C.
b. Deploy module when DAB cover surface reaches the deployment temperature given in Table 2. Dual
stage modules shall be activated with the following delay between first and second stages. For DV level
testing, use 0 ms delay and for PV level testing, use program specific delay (if not specified use 5 ms for
PV).
Table 2: Hot Deployment Temperatures for PAB/KAB System Static Deployment Test
Soak Temperature Deployment

Part
in °C Temperature in °C
Windshield Inner +75 +57
Deployment Door +102 +93

(horizontal/top mount PAB heating blanket)
Deployment Door +75 +65

(vertical/mid mount PAB, KAB)
PAB/KAB Housing +75 +75
DAB module “A” surface +85 +75

Note: The responsible VEC may substitute vehicle specific temperatures for the PAB Deployment Door and PAB Housing soak
temperature requirement.
Evaluation and Results. Module shall meet the functional requirements stated in GMW3109. Any feature
(e.g. LRD, active vent) for modifying or directing deployment energy for out-of-position occupants shall exhibit
intended functionality in video coverage recorded during the test. If intended functionality cannot be evaluated
in video coverage, the responsible VEC may specify additional tests to evaluate module performance. Module
traceability bar code and label legibility shall meet the requirements stated in GMW3109 paragraph “Label
Legibility“. The responsible VEC shall be the final arbiter of DAB/PAB/KAB System Static Deployment Testing.
3.2.1.1.2.2 DAB/PAB/KAB System Static Deployment Test – Cold.
Test Procedure.
a. Condition DAB/ PAB/KAB System at -30 °C.
b. Actuate each DAB/PAB/KAB System system with the minimum actuation current (1.2 A). The system shall
be deployed, when module cover surface temperature reaches -20 °C after system exposure to ambient
environment. No additional heating/cooling shall be used other than ambient air. Camera lighting may be
used immediately prior to deployment. Dual stage modules shall be activated with a 0 ms delay between
first and second stages for DV and a program specific delay for PV (if not defined 5 ms for PV).
c. Test facility to complete and retain post test documentation indefinitely; see Appendix A
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traceability bar code and label legibility shall meet the requirements stated in GMW3109, paragraph “Label
3.2.1.1.2.3 DAB/PAB/KAB System Static Deployment Test – Ambient.
Test Procedure.
a. Condition DAB/ PAB/KAB System at +23 °C.
b. Monitor deployment door/top pad and maintain +23 °C.
c. Deploy Module at +23 °C Dual stage modules shall be activated with a 0 ms delay between first and
second stages for DV and a program specific delay for PV (if not defined use 5 ms for PV).
d. Test facility to complete and retain post test documentation indefinitely; see Appendix A
traceability bar code and label legibility shall meet the requirements stated in GMW3109 paragraph “Label
3.2.1.2 DAB/PAB/KAB Module Sequential/Environmental Test.
Purpose. To evaluate the Module performance in a series of different environments.
Refer to paragraph 4.2 “Validation Plan” for the number of test samples to use in each test.
Notes:
a. The Airbag (AB) Module samples used in the Sequential/Environmental Tests shall include design intent
wire harnesses with connectors. DAB Module samples shall include the wire harnesses (i.e. column coil)
with DAB connectors and steering wheels.
b. For the DAB Module, the Sequential/Environmental Tests shall be run with the DAB module installed in the
Steering Wheel as a DAB/Steering Wheel system, and they shall be conditioned together. Due to
differences in the number of samples required (refer to GMW14096), extra steering wheels are required.
The parts being used to fulfill the Sequential/Environmental test requirements shall only be conditioned
and tested once. The extra steering wheels may be conditioned and tested more than once, but shall be
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3.2.1.2.1 Dynamic Shock Test.

Purpose. To evaluate the effects of mechanical shock inputs on Module performance.
Note: DAB only: When the steering wheel and driver airbag are being validated together, or if the horn system
is part of the DAB, then run the 12G Dynamic Shock test in GMW14096 on the number of samples specified in
GMW14096, and mark the samples used for later identification. Then proceed with the 25G and 45G test
below. Extra steering wheels should be used for testing the 25G or 45G parts. These steering wheels can be
reused. Number of samples should be split between High G and Low G acceleration per validation matrix
according to paragraph 4.2.
a. Rigid fixture that represents the in-vehicle Module orientation and design intent mounting.
b. Shaker.
c. Electrical fixture to record horn actuation and duration for Driver Airbag Modules/Steering Wheel
assemblies, and a palm-sized indenter to measure insertion force to fully seat the Module with the Steering
Wheel (with visual confirmation of engagement).
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Table 3: DAB, PAB and KAB Dynamic Shock Schedule
Low G Test High G Test
Acceleration: 25G Acceleration: 45G

Nominal Shock Duration:6 ms Nominal Shock Duration:11 ms
Nominal Shock Shape: Half Sine Nominal Shock Shape: Half Sine
Number of Shock Per Axis: 330 Number of Shock Per Axis: 3
1980 total 18 total

6 axes: x, y, and z, both positive and negative 6 axes: x, y, and z, both positive and negative
directions directions
Modules shall represent in-vehicle orientation Modules shall represent in-vehicle orientation
Test Method: Test Method:

1. Apply 25G 330 times per axis (x, -x, y, -y, z, -z). 1. Apply 45G 3 times per axis (x, -x, y, -y, z, -z).
2. Change axis and repeat step 1. 2. Change axis and repeat step 1.
3. Repeat steps 1 and step 2 until all 6 axes are 3. Repeat steps 1 and step 2 until all 6 axes are
tested. tested.
Test Procedure.
a. Condition Modules at +23 °C as specified in paragraph 4.2 “Validation Plan”.
b. If horn mechanism is part of DAB module, complete horn effort test GMW14595).
c. Refer to IEC 60068-2-27 Ea for complete test procedure. Complete the dynamic shock test according to
Table 3. For the Driver Airbag Modules, measure DAB insertion forces each time a new steering wheel is
used according to paragraph 3.2, and continuously monitor horn during the test for actuation.
d. Verify Module electrical resistance, shunt resistance, and insulation resistance according to
paragraph 3.2.1.1, step f.
Evaluation and Results. The module shall meet the Vibration and Dynamic Shock Resistance requirement
stated in GMW3109, paragraph “Vibration and Dynamic Shock Resistance”. The Module shall not be visibly
damaged and shall meet the Cover/Door appearance requirements stated in GMW3109, paragraph “Visible
Cover/Door Appearance”. The module shall meet Push-in/Snap-in Attachment Insertion/Removal Cycles
stated in GMW3109, paragraph “Push-in/Snap-in Attachment Insertion/Removal Cycles and Forces”.
Note: 12G test only: The Driver Airbag Module/Steering Wheel system shall meet the Horn Inadvertent
Actuation requirements according to GMW3109, paragraph “Horn Inadvertent Actuation”. Horn contact
duration shall be < 5 ms (millisecond).
All noted discrepancies shall be documented and reported to the Responsible VEC Engineer.
3.2.1.2.2 Vibration/Temperature Cycle Test.
Purpose. To evaluate the effect of vibration and temperature on Module performance.
a. Temperature chambers, capable of maintaining (-30 to +85) °C.
b. Rigid fixture that represents the in-vehicle Module orientation and design intent mounting.
c. Shaker.
Test Procedure.
a. Complete Dynamic Shock Test according to paragraph 3.2.1.2.1.
b. Condition all Modules at +23 °C, as specified in paragraph 4.2 “Validation Plan”
c. Refer to IEC 60068-2-64, and IEC 60068-2-14 Nb for complete test procedure. Apply the applicable
random vibration profile shown in Table 4 for 22 h in the vehicle X-axis (Module shall represent in-vehicle
orientation, see Figure 6).
d. Apply temperature cycle shown in Figure 7 twice per axis during vibration testing. One temperature cycle
consists of:
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1. Drop temperature to -30 °C at the rate of 2 °C/minute.

2. Condition Modules for 272.5 minutes at -30 °C.
3. Raise temperature to +85 °C at the rate of 2 °C/minute.
4. Condition Modules for 272.5 minutes at +85 °C.
5. Bring Modules to +23 °C at the rate of 2 °C/minute.
e. Verify Module electrical resistance, shunt resistance, and insulation resistance according to
paragraph 3.2.1.1 “Module Static Deployment test”, step f.
f. Condition Modules at +23 °C, as specified in paragraph 4.2 “Validation Plan”. Change vibration direction to
the vehicle Y-axis (Module shall represent in-vehicle orientation), repeat steps 3 and 4.
g. Condition Modules at +23 °C, as specified in paragraph 4.2 “Validation Plan”. Change vibration direction to
the vehicle Z-axis (Module shall represent in-vehicle orientation), repeat steps 3 and 4.
Figure 6: Vehicle Axes
(positive up) Z
(positive Y
cross car)
X (positive rearward)
Table 4: DAB, PAB and KAB Vibration Profile
Driver Airbag Passenger Airbag Knee Airbag

2 2 2
Hz g /Hz Hz g /Hz Hz g /Hz
10 1.37E-01 10 1.37E-01 10 1.37E-01
95 5.41E-03 95 5.41E-03 95 5.41E-03
216 5.30E-03 216 5.30E-03 216 5.30E-03
465 3.89E-04 465 3.89E-04 465 3.89E-04
645 3.14E-05 645 3.14E-05 645 3.14E-05
685 1.82E-04 685 1.82E-04 685 1.82E-04
1000 8.37E-06 1000 8.37E-06 1000 8.37E-06
Total Eff. Acc. Total Eff. Acc. Total Eff. Acc.

1.75 grms 1.75 grms 1.75 grms
(10 to 1000 Hz): (10 to 1000 Hz): (10 to 1000 Hz):
Figure 7: DAB, PAB and KAB Temperature Profile
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Evaluation and Results. The Module shall meet the Vibration/Temperature requirements stated in
GMW3109, paragraph “Vibration and Dynamic Shock Resistance”. The Module shall not be visibly damaged
and shall meet the Cover/Door appearance requirements stated in GMW3109, paragraph “Visible Cover/Door
Appearance”. All noted discrepancies shall be documented and reported to the responsible VEC Engineer.
3.2.1.2.3 Thermal Shock Test.
Purpose. To evaluate performance effects on materials within the Module due to rapid temperature changes.
a. Temperature chambers, capable of maintaining -30 °C, +23 °C, and +85 °C.
b. Fixture that represents the in-vehicle Module orientation and the mounting.
c. Electrical fixture to record horn actuation and duration for Driver Airbag Modules/Steering Wheel
assemblies.
Test Procedure.
a. Complete Vibration/Temperature Test, paragraph 3.2.1.2.2.
b. Condition all Modules at +23 °C as specified in paragraph 4.2.”Validation Plan”
c. Refer to IEC 60068-2-14 Na for complete test procedure. Apply 60 temperature cycles as shown in
Figure 8. One (1) temperature cycle consists of:
1. Place Module into -30 °C chamber within 30 s.
2. Condition Module assemblies at -30 °C as specified in paragraph 4.2.
3. Place Module into +85 °C chamber within 30 s.
4. Condition Module assemblies at +85 °C specified in paragraph 4.2.
5. Continuously Monitor Horn continuity during test.
paragraph 3.2.1.1.1, “Module Static Deployment Test”, step f.
Evaluation and Results. The Module shall not be visibly damaged and shall meet the Cover/Door
appearance requirements stated in GMW3109, paragraph “Visible Cover/Door Appearance”. The Driver Airbag
Module shall meet the Horn Inadvertent Actuation requirements per GMW3109, paragraph “Horn Inadvertent
Actuation”. All noted discrepancies shall be documented and reported to the responsible VEC Engineer.
Figure 8: DAB, PAB and KAB Thermal Shock Profile
Thermal Shock Temperature Cycle

The Core Temperature within airbag module Shall Reach the Specified Temperature
100
80
Temperature60
Degrees C
40
20
0
0 1 2 3 4 5 6 7 8 9
-20
-40
Hours
Note 1: Thermal Shock Temperature Cycle: Core temperature within Module shall reach the specified temperature.
The Cycle duration may be reduced if the inflator core temperature reaches the temperature specified in Figure 8 in < 4 h shown. Data
shall be provided to verify any changes to the cycle duration. Refer to paragraph 3.2.1.1.1.
Note 2: Temperature in °C
3.2.1.2.4 Humidity Resistance Test.

Purpose. To evaluate the effect of humidity on Module performance.
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December 2012
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a. Temperature chambers, capable of maintaining -10 °C and +65 °C, and up to 100 % RH.
b. Fixture that represents the in-vehicle Module orientation and the mounting system.
c. Electrical fixture to record horn actuation and duration (Driver Airbag Module only).
Test Procedure.
a. Complete Thermal Shock Test according to paragraph 3.2.1.2.3.
b. Condition Modules at +23 °C, as specified in paragraph 4.2 “Validation Plan”.
c. Refer to IEC 60068-2-38 Z/AD for complete test procedure.
Condition Module for 244 h with temperatures of:
-10 °C, +23 °C, +65 °C and with 95 % maximum RH according to Figure 9.
The following steps briefly describe the procedure for this test. Refer to IEC 60068-2-38 for detailed test
procedure. Continuously monitor horn continuity during test cycle (For DAB Modules in which horn actuation is
achieved through Module movement or DAB Modules with horn actuation Subcomponents):
a. Modules shall complete four cycles of phase one conditioning for total of 96 h. During this phase, the
relative humidity level shall be 90 % minimum except during the temperature transitions when the
minimum RH level shall be 80 %.
b. Modules shall complete five cycles of phase two conditioning for total of 130 h. The relative humidity level
shall be 90 % minimum except during the temperature transitions, when the minimum RH level shall be
80 %. The relative humidity cannot be controlled when the temperature is < +20 °C.
c. Modules shall complete one cycle of phase three conditioning for total of 18 h. During this phase, the
relative humidity level shall be 90 % minimum except during the temperature transitions, when the
minimum RH level shall be 80 %. The relative humidity cannot be controlled when the temperature is
< +20 °C.
paragraph 3.2.1.1.1 “Module Static Deployment Test”, step f.
Evaluation and Results. The Module shall meet the Humidity Resistance requirements stated in GMW3109,
paragraph “Humidity Resistance”. The Driver Airbag Module shall meet the Horn Inadvertent Actuation
requirements according to GMW3109 paragraph “Horn Inadvertent Actuation”.
Figure 9: DAB, PAB and KAB Humidity Profile
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3.2.1.2.5 Salt Spray Test.

Purpose. To evaluate the corrosion resistance of the Module.
a. Refer to GMW3286 for complete list of equipment.
b. Fixture that represents the in-vehicle Module orientation and the mounting system.
Test Procedure.
a. Complete Humidity Resistance Test according to paragraph 3.2.1.2.4.
b. For Driver Airbag Module, install Module in the design representative Steering Wheel.
c. Condition Modules at +23 °C, as specified in paragraph 4.2.
d. Condition Modules 24 h minimum with 5 % salt solution per GMW3286 procedures.
e. Modules shall not be cleaned or have surface corrosion wiped off after this test.
f. Verify Module electrical resistance, shunt resistance, and insulation resistance according to
paragraph 3.2.1.1.1 “Module Static Deployment Test” step f.
Evaluation and Results. The Module shall meet the Salt Spray Resistance requirements stated in GMW3109,
paragraph “Salt Spray Resistance”. All noted discrepancies shall be documented and reported to the
responsible VEC Engineer. For Driver Module, the Horn assembly shall meet the operational requirement
according to GMW14599.
3.2.1.2.6 Service Durability Test.
Purpose. To evaluate service durability performance for modules with structural fasteners.
a. Steering Wheel and Module Assembly or Instrument Panel and Module Assembly that represents in-
vehicle Module orientation and design intent mounting.
b. A Palm-sized indenter to measure insertion forces to fully seat the Module with the Steering Wheel or
Instrument Panel structure.
Test Procedure.
a. Complete Salt Spray Resistance Test according to paragraph 3.2.1.2.5.
b. Condition Modules at +23 °C as specified in paragraph 4.2.
c. Perform a service durability cycle test as shown in Table 5. Each cycle consists of following steps:
1. Disconnect all electrical connectors at the Module and harness interface. Remove Module from,
Steering Wheel, Instrument Panel or knee bolster.
2. Attach Module to the Steering Wheel, Instrument Panel or knee bolster. Measure the total insertion
force.
3. Reconnect all electrical connectors. Verify connector mating.
paragraph 3.2.1.1.1, step f.
Table 5: DAB, PAB and KAB Service Durability Cycle – Post Conditioning
Driver Airbag Passenger Airbag Knee Airbag
10 3 5
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Cycles
Evaluation and Results. Modules shall meet the Attachment Insertion/Removal Cycles requirements stated in
GMW3109, paragraph “Push-in/Snap-in Attachment Insertion/Removal Cycles and Forces”.
3.2.1.2.7 Squeak, Rattle, and Other Audible Noise Avoidance Test.
Purpose. To evaluate if there is any discernible noise originating from the Airbag Module.
Test Fixtures and Equipment. Refer to GMW14011 for appropriate test fixture and equipment.
GM Confidential
Test Procedure.
a. Complete Service Durability Test according to paragraph 3.2.1.2.6.
b. Condition 6 Modules (3 from the High G and 3 from the Low G groups) at +23 °C as specified in
paragraph 4.2.
c. Perform objective evaluation of the Module Noise as described in GMW14011 using the vibration spectrum
shown in Table 6. The DAB Shall be installed in the steering wheel for this evaluation, and shall use the
vibration profile described in the Steering Wheel Specification GMW14096 “Noise Test”.
Evaluation and Results. Modules shall meet the Module Squeak, Rattle, and Other Audible Noise Avoidance
requirements stated in GMW3109; “Squeak, Rattle, and Other Audible Noise Avoidance – Component Level”.
Table 6: DAB, PAB and KAB Vibration Profile for Squeak,
Rattle, and Other Audible Noise Avoidance Test
DAB see steering wheel specification GMW14096
Passenger and Knee Airbag Modules
Vertical Acceleration Fore-Aft Acceleration Lateral Acceleration
Frequency Acceleration Frequency Acceleration Frequency Acceleration

in Hz in (m/s2)2/Hz in Hz in (m/s2)2/Hz in Hz in (m/s2)2/Hz
8 0.24082 8 0.15361 8 0.11766
12 1.21161 11 0.40492 14 0.25918
22 0.24264 19 0.27314 19 0.10301
32 0.12420 31 0.07758 36 0.11153
41 0.15867 41 0.15436 53 0.11433
57 0.20387 58 0.15334 81 0.03191
72 0.06704 71 0.04148 100 0.00057

2
100 0.00029 100 0.00022 m/s RMS 2.75
2 2
m/s RMS 4.03 m/s RMS 3.21
3.2.1.2.8 Module Deployment.
a. Complete Squeak, Rattle, and Other Audible Noise Avoidance Test according to paragraph 3.2.1.2.7.
b. Randomly select one Module from the High G shock test group (45G) for static teardown.
c. Perform Static Deployment on the remaining Modules, per Module Deployment Test according to
paragraph 3.2.1.1.
Evaluation and Results. Module shall meet the functional requirements stated in GMW3109, “Module
Deployment Performance”.
3.2.1.3 Heat Aging.
3.2.1.3.1 Module Heat Aging - Low Humidity Test.
Purpose. To evaluate the Module resistance to temperature aging in a dry condition.
Temperature chambers, capable of maintaining up to +107 °C and up to 20 % RH.
Test Procedure DAB/KAB/PAB Modules.
a. Option 1: Condition Modules at +90 °C for 1000 h with up to 20 % RH or:
b. Option 2: Condition Modules at +95 °C for 720 h with up to 20 % RH or:
c. Option 3: Condition Modules at +107 °C for 408 h with up to 20 % RH.
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e. Perform Static Deployment on the Modules, per Module Deployment Test according to paragraph 3.2.1.1.
3.2.1.3.2 System level Heat Aging- Low Humidity test.
Purpose. To evaluate the system level resistance to temperature aging in a dry condition for PAB/KAB
Modules (with Airbag Door Integral to the IP System).
Note:
a. Assemble the system-level test samples (including airbag modules), then condition them to the appropriate
subsystem conditioning shown in Table 7. Door/IP System shall be conditioned according to Table 7.
b. Assemble module to Door/IP System.
c. Verify Module electrical resistance, shunt resistance, and insulation resistance according to
d. Perform Static Deployment on the PAB System (Module and Door/IP system), per Module Deployment
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Test according to paragraph 3.2.1.1. Deploy within 2 weeks from conditioning. If any module components
are hydroscopic (nylon for example), store at room temperature and 50 % RH.
Evaluation and Results. Module shall meet the Module performance requirements after Heat Aging, stated in
GMW3109, “Module Performance after Heat Aging”. Any feature for modifying or directing deployment energy
for out-of-position occupants shall exhibit intended functionality in video coverage recorded during the test. If
intended functionality cannot be evaluated in video coverage, the responsible VEC may specify additional tests
to evaluate module performance.
Table 7: System Conditioning for Heat Age – Low Humidity Test
Time
System Glass type Temperature Relative Humidity
in h
IP Top Mount Solar Glass +102 °C <5% 400 h

PAB/KAB Tinted Glass +110 °C
Non-Top Mount N/A +85 °C <5% 400 h

(KAB Included)
3.2.1.3.3 Module Heat Aging - High Humidity Test.

Purpose. To evaluate the Module resistance to temperature aging in a humid condition. For all modules with
or without Door on Module (DOM).
Test Fixtures and Equipment. Temperature chambers, capable of maintaining +70 °C and up to 95 % RH
(Option 1) or +75 °C and up to 75 % RH (Option 2).
Test Procedure.
a. Option 1: Condition all Modules at +70 °C, 95 % RH for 408 h or:
Option 2: Condition all Modules at +75 °C, 75 % RH for 750 h.
b. Verify Module electrical resistance, shunt resistance, and insulation resistance according to
c. Perform Static Deployment on the Modules, per Module Static Deployment Test according to
paragraph 3.2.1.1.
Notes:
Module Static Deployment shall be scheduled such that deployments shall begin within 2 weeks from
conditioning if any module components are hydroscopic (nylon for example). Store at room temperature
and 50 % RH.
Airbags validated to either option are acceptable to all GM regions. The supplier shall refer to the
responsible VEC Engineer to determine which option to use.
GM Confidential
Evaluation and Results. Module shall meet the Module performance requirements after Heat Aging, stated in
GMW3109, “Module Performance after Heat Aging”. Any feature for modifying or directing deployment energy
for out-of-position occupants shall exhibit intended functionality in video coverage recorded during the test. If
intended functionality cannot be evaluated in video coverage, the responsible VEC may specify additional tests
to evaluate module performance.
3.2.1.4 Conformité Européene (CE) Conformity Pyrotechnic Directive 2007/23/EC. Follow CE conformity
procedure per pyrotechnic directive 2007/23/EC.
3.2.1.5 Module Drop Test.
Purpose. To evaluate the Module performance after withstanding the Module drop test.
a. Fixtures to drop Modules from 1.2 m and 2.5 m.
b. Rigid steel plate, larger than the size of the Module.
c. Test chamber, capable of maintaining +23 °C.
Test Procedure: 2.5 m Drop.
a. Condition Modules at +23 °C as specified in paragraph 4.2.
c. Select one Module randomly and perform drop from (2.5 ± 0.01) m (lowest point of the Module at 2.5 m
height) at +23 °C onto the rigid steel plate. Drop the module as follows:
d. Drop once with the initiator(s) in the down position and once perpendicular to the first, and orientated so
the inflator is at its lowest point. For dual stage Modules with initiators located at opposite ends of the
inflator, perform 3 drops for this module. Drop once with each initiator in down position. The third drop shall
be in the direction perpendicular to the axis of the both initiators (center pin to center pin), and orientated
so the inflator is at its lowest point. The module shall not deploy from the 2.5 m drop.
e. Visually inspect the inflator, baseplate/housing, electrical connector, lead wire, cover/door
retention/integrity/show surface, and fasteners for damage. All visual damage shall be documented and
reviewed with the responsible VEC Engineer. Retain this Module for inspection and static teardown.
Test Procedure: 1.2 m Drop.
a. Condition Modules at +23 °C as specified in paragraph 4.2.
b. Verify Module electrical resistance, shunt resistance, and insulation resistance per according to
c. Perform drop from (1.2 ± 0.01) m (lowest point of the Module at 1.2 m height) at +23 °C onto the rigid steel
plate. Drop the modules as follows: Once with the initiator(s) in the down position, and once perpendicular
to the first, and orientated so the inflator is at its lowest point. For dual stage Modules with initiators located
at opposite ends of the inflator, perform 3 drops per module. Drop once with each initiator in down position.
The third drop shall be in the direction perpendicular to the axis of the both initiators (center pin to center
pin), and orientated so the inflator is at its lowest point.
d. Visually inspect the inflator, baseplate/housing, electrical connector, lead wire, cover/door
retention/integrity/show surface, and fasteners for damage. All visual damage shall be documented and
reviewed with the responsible VEC Engineer prior to static deployment test.
e. Verify Module electrical resistance, shunt resistance, and insulation resistance according to
paragraph 3.2.1.1.1, “Module Static Deployment Test” step f.
f. Perform Static Deployment on the Modules, per Module Static Deployment Test according to
paragraph 3.2.1 and 3.2.1.1. All deployments shall be performed at +23 °C.
Evaluation and Results. Module shall meet the Module Mechanical Drop requirements stated in GMW3109,
paragraph “Drop Resistance”.
3.2.1.6 Module Effluent Test.
Purpose. To evaluate Module particulate and effluent gas levels.
Test Fixtures and Equipment. Refer to USCAR-24 and SAE J1794 for complete list of equipment.
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Test Procedure.
a. Condition Modules at +23 °C, as specified in paragraph 4.2.
b. Perform effluent test as specified in USCAR-24 “Gas sampling and analysis”.
Note: For Dual stage Modules, they shall be evaluated at
a. High level.
b. Primary inflator output only with 100ms discharge of secondary output (if appropriate and/or
required by VEC)
c. Low level.
Evaluation and Results. Effluent and particulate levels shall meet the requirements stated in GMW3109,
paragraph “Effluents”.
3.2.1.7 Solar Exposure Test.

Purpose. To evaluate the appearance of the Module Cover/Door after Solar exposure and/or Ultraviolet (UV)
light. VEC approval is required for appropriate test procedure.
Notes:
This test is required only for modules with Class ‘A’ deployment doors.
A minimum of two modules per Cover/Door color shall be provided for Solar Exposure Testing. A minimum
of one Cover/Door shall be used for testing, and one Cover/Door shall be used for control purposes.
a. Solar Tracking preferred.
b. Fixture to provide the in-vehicle orientation for the Modules.
c. Test Equipment and Fixtures as specified in GMW3417 and GMW14162
Test Procedure - Solar Exposure.
b. Condition Modules for light Exposure as described in GMW3417. Condition Modules to the 5-year light
exposure duration specified for the windshield construction used in the vehicle per GMW3109 “Solar
Exposure Resistance” (or GMW14444)
c. Visually inspect Modules after solar exposure.
Test Procedure - UV Exposure.
b. Refer to GMW14162 for the complete test procedure. Condition Modules for UV exposures as described in
GMW3109, “Solar Exposure Resistance”.
c. Visually inspect Modules after exposure of 0.3 MJ/m2 and 1.5 MJ/m2.
Evaluation and Results. The Module Cover/Door shall meet Solar Exposure Resistance requirements stated
in GMW3109, “Solar Exposure Resistance”.
3.2.1.8 Ozone Exposure Test.
Purpose. To evaluate Module components for deterioration due to ozone exposure, for Modules with
components external to the inflator that contain potentially elastomeric ozone-sensitive materials (e.g. inflator
tuned absorber).
Test Fixtures and Equipment. Refer to ISO 1431-1 for complete list of equipment.
Test Procedure.
b. Perform ozone test per or ISO 1431-1.
c. Verify Modules' electrical resistance, shunt resistance, and insulation resistance according to
d. Perform Static Deployment on the Modules, per “Module Static Deployment Test” according to
paragraph 3.2.1.1.
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Evaluation and Results. The Module shall meet the Ozone Resistance requirements stated in GMW3109,
“Ozone Resistance”.
3.2.1.9 Module Electrical Stress Test.
Purpose. To evaluate Module immunity to electrostatic discharge.
Test Fixtures and Equipment. Refer to GMW3097 for complete list of equipment.
Test Procedure.
a. Condition Modules at +23 °C, as specified in paragraph 4.2 “Validation Plan”.
b. Condition all Modules per GMW3097 procedure. The Responsible VEC Engineer shall define accessible
discharge point.
c. Verify Module electrical resistance, shunt resistance, and insulation resistance according to
Evaluation and Results. The Module shall meet the Electrical Stress requirements stated in GMW3109,
“Electrical Stress”.
3.2.1.10 Module Fatigue Resistance Test.

Purpose. To evaluate the Airbag Door/Cover Fatigue resistance for Modules with Class ‘A’ Door/Covers.
a. PAB and KAB: (100 ± 5) mm diameter fatigue fixture, 50 mm in length.

b. DAB: (19 ± 1) mm diameter, hemispherical in design.
c. Load cell, 4450 N (1000 lb) range, with thread adapters.
d. Chart recorder.
e. Linear actuator system of closed loop control or stroke control.
f. Appropriate fixture to support steering wheel, IP or section of the IP to simulate production (intent)
attachment to the vehicle.
Test Procedure.
b. Responsible VEC shall define a single point per GMW3109, “Fatigue Resistance”.
c. Refer to Table 8 for appropriate test fixture, load and cycle.
d. Align the hydraulic actuator and the center of the fixture perpendicular to the Airbag Door/Cover.
Depending on the design, the loading shall be done on the center of tear seam or the center of the door
hinges. VEC will define the test location.
e. Run the hydraulic actuator in stroke control to attain an initial compression load as specified in Table 8.
Cycle sinusoidally at 1 Hz. Record the load on a strip chart recorder at a chart speed of 0.5 mm/s.
f. Run the test per Table 8 requirements.
g. Visually inspect the door for damage and record observations. Any discrepancies noted shall be
documented and reported to the responsible VEC engineer.
h. Indicate the test request and title, operator, date, load and time scales, and the minimum load on the strip
chart recorder.
Evaluation and Results. The Airbag Door/Cover shall meet the “Fatigue Resistance” requirements stated in
GMW3109.
Table 8: DAB, PAB and KAB Fatigue Fixture, Load and Cycle
Fatigue Fixture Load

Total Cycle
in mm in N
DAB 19 ± 1 50 ± 1 50 000 --```,``,`,,,`,``````,,-`-`,,`,,`,`,,`---
PAB 100 ± 5 100 ± 2 4000

KAB 100 ± 5 100 ± 2 4000
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3.2.1.11 Horn Tests.

Note: These tests apply to DAB Modules with horn actuation subcomponents only.
3.2.1.11.1 Horn Durability Cycle Test.
Purpose. To evaluate the effect of temperature on the durability of the horn mechanism.
Test Fixtures and Equipment. Refer to GMW14599 procedures for complete list of equipment.
DAB Module and Steering Wheel Assemblies.
Test Procedure.
a. Responsible VEC Engineer shall define a test location GMW3109, “Horn Actuation Target Area”.
b. Perform a total of 50 000 cycles per GMW14599
Note: For Emerging market a total of 500 000 (250 000 each of two locations. One the bugle and one at
the geometric center of the horn mechanism).
c. Horn continuity shall be monitored continuously during testing.
Evaluation and Results. The Module Horn Actuation subcomponent(s) shall meet the Horn Durability
requirement stated in GMW3109, “Horn Durability”.
Modules and steering wheel shall not exhibit any deformation. The horn shall meet the operational requirement
according to GMW14599.
3.2.1.11.2 Horn Actuation Moisture and Temperature Sensitivity Test.
Purpose. To evaluate the sensitivity of the Module horn actuation mechanism to moisture and temperatures.
Refer to Thermal shock and humidity sections of sequential testing for complete list of equipment.
Test Procedure.
a. Responsible VEC shall define a maximum of 10 points (including bugles) per GMW3109, “Horn Actuation
Target Area”.
b. Moisture and Temperature Sensitivity testing will occur concurrent with sequential testing.
Evaluation and Results. The Module Horn Actuation subcomponents shall meet the Horn
Temperature/Humidity Sensitivity requirement stated in GMW3109, “Horn Blowing Mechanism Moisture and
Temperature Sensitivity”.
3.2.1.11.3 Horn Actuation Effort Test.
Purpose. To evaluate the effort required to activate the horn actuation mechanism.
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Refer to GMW14595 for complete list of equipment.

Test Procedure.
a. Responsible VEC Engineer shall define a maximum of ten points (including bugles) per GMW3109, “Horn
Actuation Target Area”.
b. Perform test per GMW14595 at -30 °C, +23 °C, and +85 °C.
Evaluation and Results. The Module Horn Actuation subcomponents shall meet the “Horn Actuation Effort”
requirement stated in GMW3109. Complete the post test requirements per GMW14595.
3.2.1.12 Module Hand Impact Resistance Test.
Purpose. Evaluate the Module Door/Cover resistance to hand impact for Modules with Class ‘A’ Door/Covers.
(76 ± 1) mm diameter, 1 kg. drop weight, as shown in Figure 10.
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Figure 10: DAB, PAB and KAB Hand Impact Test Fixture
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1 76 mm Diameter
2 Steel Ballast
3 Aluminum Nose
4 38 mm Radius
Test Procedure.
b. Align the Module Door/Cover under the drop fixture such that the drop test fixture is perpendicular to the
Door/Cover. Door shall be in the following areas:
1. The largest unsupported area of the Door/Cover.
2. At the location of Door/Cover static retention mechanisms, and at any unsupported seam areas.
c. Drop the 76 mm diameter weight from a height of (900 ± 5) mm on to the Door/Cover once.
d. Perform visual inspection of the door/cover and record observation. Any noted discrepancies shall be
documented and reported to the responsible VEC Engineer.
e. Retain modules for inspection, and tear down or deployment as directed by the responsible VEC Engineer.
Evaluation and Results. The Module shall meet the “Hand Impact Resistance” requirement stated in
GMW3109.
3.2.1.13 Module and Door/Cover Finger Indentation Resistance Test.
Purpose. Evaluate the Module Door/Cover resistance to finger indentation for Modules with Class ‘A’/’B”
Door/Covers.
a. Load cell, 4450 N (1000 lb) range, with thread adapters.
b. Linear actuator system of closed loop control or stroke control.
c. (19 ± 0.5) mm finger fixture, ≈83 mm in length, as shown in Figure 11.
GM Confidential
Figure 11: DAB, PAB and KAB Finger Indentation Test Fixture
83 mm
5/8 – 11 Thd., 16 mm deep R = 9.5 mm
Test Procedure
b. Align the hydraulic actuator and 19 mm diameter rod perpendicular to the Module Door/Cover. Position the
indenter to the center of the largest unsupported area of the door cover. This test shall also be conducted
on any unsupported tear seam areas.
c. Manually advance the indenter in stroke control until the strip chart recorder indicates (150 ± 2) N
compression. Maintain position of the indenter for 15 s and return then return to its original position (zero
loading position on the strip chart recorder).
d. The Door/Cover shall not deform, bend, crack, sag, distort, or fragment after applying a load of (150 ± 2) N
using the 19 mm indenter tool. Perform visual inspection of the Door/Cover and record observation. Any
discrepancies noted shall be documented and reported to the responsible VEC Engineer.
e. Retain modules for inspection, and tear down or deployment as directed by the responsible VEC Engineer.
Evaluation and Results. The Module shall meet the “Finger Indentation Resistance” requirement stated in
GMW3109.
3.2.1.14 PAB/KAB Module Pry Resistance Test.
Purpose. To evaluate the PAB/KAB Module resistance to prying. This test applies only to PAB/KAB Modules
with visible Class ‘A’ door/covers.
Test Fixtures and Equipment. Pry fixture 25.4 mm x 1.6 mm x 76 mm, as shown in Figure 12.
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Figure 12: PAB/KAB Pry Test Fixture
1 76 mm
2 12.7 mm Radius
3 25.4 mm
Test Procedure.
b. Insert the pry fixture into the lower right corner of the PAB Module Door, at its perimeter, to the full
allowable depth.
c. Orient the Module such that the pry fixture is perpendicular to the Module door.
d. Rotate pry fixture away from the Door until it becomes parallel to the door surface.
e. Perform visual inspection of the Door and record observation. Any discrepancies noted shall be
documented and reported to the responsible VEC Engineer.
f. Retain modules for inspection, and tear down or deployment as directed by the responsible VEC Engineer.
Evaluation and Results. The Module shall meet the “Pry Resistance” requirement stated in GMW3109.
3.2.1.15 Module Integrity Test DAB/PAB/KAB.
Purpose. To evaluate the Integrity of the Module Cushion Assembly in a dynamic environment.
Note: Not required for Emerging market applications.
Test Fixtures and Equipment. DAB/PAB.
a. Drop tower or equivalent fixture capable of providing maximum 2.0 kJ energy to the Module.
b. Body block to represent a 95 percentile anthropomorphic Test Device (ATD) upper torso dimensions.
c. Total mass of drop head (body block and fixture) of 44 kg.
d. Rigid fixture that represents in-vehicle Module orientation and mounting scheme.
e. High Speed cameras (1000 frames/s minimum). Standard camera coverage is one camera on either side.
For PAB modules containing any feature for modifying or directing deployment energy for out-of-position
occupants, additional camera views may be required at the discretion of the responsible VEC to view and
evaluate this feature. Each camera shall have a lens which allows a full view of the Module and inflated
cushion.
Test Procedure.
a. Condition Modules at +85 °C for DAB and +75 °C for PAB as specified in paragraph 4.2.
c. Mount the Module in a rigid fixture, with the components that normally surround it including reaction
surfaces, to the extent possible.
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d. The falling drop head shall have a velocity of 7.5 m/s at the time of contact with the Module.
Note: The responsible VEC may substitute a different mass for the drop head to meet vehicle specific
loading condition of the Module.
e. The module shall be deployed 2 minutes after removing from conditioning chamber using 1.2 A DC, and
loading shall begin when the cushion reaches maximum pressure and extension of cushion. Pressure taps
are not allowed on the tested Module. The following data shall be provided:
1. Acceleration of the drop head
2. Acceleration as a function of displacement
3. Velocity of drop head as a function of displacement
4. Video documenting the test
Test Fixtures and Equipment – KAB (Figure 13)
a. Drop tower or equivalent fixture capable of providing 1.0 kJ maximum energy to the Module.
b. Impactor surface to represent the lower legs, consisting of two (2) 100 mm diameter cylinders of 600 mm
length, with a centerline spacing of 200 mm.
Figure 13: KAB Impact Fixture
c. The Impactor cylinders shall be centered on the cushion.

d. Total mass of impactor (Impactor surface and fixture) of 64 kg.
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e. Rigid fixture (KAB reaction surface) that represents in-vehicle Module orientation and mounting scheme.
f. The Impactor travel direction shall be normal to the reaction surface.
g. High Speed cameras (1000 frames/s minimum). Standard camera coverage is one camera on either side.
Each camera shall have a lens which allows a full view of the Module and inflated cushion.
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Test Procedure.
c. Mount the Module in a rigid fixture, with the components that normally surround it including reaction
surfaces, to the extent possible.
d. The impactor shall have a velocity of 5 m/s at the time of contact with the Module.
Note: The Responsible VEC(s) may substitute a different mass for the impactor to meet vehicle specific
loading condition of the Module.
e. The module shall be deployed 2 minutes after removing from conditioning chamber using 1.2 A DC, and
loading shall begin when the cushion reaches maximum pressure and extension of cushion. Pressure taps
are not allowed on the tested Module.
f. The following data shall be provided:
1. Acceleration of the impactor
2. Acceleration as a function of displacement
3. Velocity of drop head as a function of displacement
4. Video documenting the test
Evaluation and Results. The Module shall meet the “Module Integrity” requirement stated in GMW3109. Any
feature for modifying or directing deployment energy for out-of-position occupants shall exhibit intended
functionality in video coverage recorded during the test. If intended functionality cannot be evaluated in video
coverage, the responsible VEC may specify additional tests to evaluate module performance.
3.2.1.16 Out-Of-Position Body Block Test for Low Risk Deployment PAB.
Purpose. To evaluate module component functionality and integrity for out-of-position occupant exposure.
Required for PAB applications where FMVSS 208 compliance is being achieved via Low Risk Deployment
(LRD) for the 6 year old ATD, and/or for the 3 year old ATD.
Note: Prior to Module assembly build, the cushion seams should be marked to outline the cushion.
a. Six year old Body Block: to represent the dimensions and weight of a six year old ATD with the legs
removed as tested in the FMVSS 208 NHTSA1 low risk deployment test condition (GM Evaluation
Considerations Book Consideration F50-III-6P).
b. Vehicle front B-I-W or a fixture approved by the responsible VEC that represents in-vehicle Module
orientation and mounting system.
c. Module mounting shall simulate vehicle environment, (built up IP) including reaction surfaces when
applicable.
d. Cover and/or door required.
e. Vehicle windshield is required if deployment door or cushion contacts windshield during deployment in this
test condition. If deployment door or cushion does not contact windshield, alternative windshield material
(i.e. Plexiglas, Lexan) may be used.
f. Actuation device that also switches on the measuring equipment.
g. Approved Data Acquisition System.
h. Test backdrop with grid.
i. High speed cameras (2000 frames/s minimum). A minimum of three cameras/videos required: Rear, side,
and oblique views. For PAB modules containing any feature for modifying or directing deployment energy
for out-of-position occupants, additional camera views may be required at the discretion of the responsible
VEC to view and evaluate this feature. Each camera shall have a lens, which allows a full view of the
Module and inflated cushion.
j. Lights (High intensity).
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k. Thermometer that can measure temperatures up to +110 °C.

l. Strobe Light (to indicate T = 0).
m. ID-labels (with test number).
Data Required.
Ambient temperature in test cell during the test
Cushion pressure vs. time if requested
Voltage and current vs. time
High speed video
Test Procedure.
a. Measure and record Module electrical resistance, insulation resistance, and shunt resistance as described
in paragraph 3.2.1.1.1 step f.
b. Connect pressure transducer to pressure tap on Module (DV Modules only if required by responsible VEC
Engineer), connect inflator squib to firing lead.
c. Build up PAB module, deployment door, IP, and windshield in the vehicle front B.I.W. Orient the body
block using the FMVSS 208 NHTSA1 six year old ATD low risk deployment test procedure (GM Evaluation
Considerations Book Consideration F50-III-6P).
d. Set up and adjust high speed cameras to allow a full view of the Module and inflated cushion. Standard
camera coverage is one camera in rear and one camera on either side. For PAB modules containing any
feature for modifying or directing deployment energy for out-of-position occupants, additional camera
views may be required at the discretion of the responsible VEC to view and evaluate this feature.
e. Set up lights in a manner that provides sufficient lighting for all camera views.
f. Set up strobe light to illuminate Module, to show T=0 on all high-speed cameras or videos.
g. Document test date, sample number and serial number. Attach ID label to front and side of the test
fixture/IP, visible in all camera views.
h. Take still photographs of Module before test.
i. Activate the data acquisition system. The following data shall be recorded:
1. Ambient temperature in test cell during the test
2. Cushion pressure vs. time if requested
3. Voltage vs. time
4. Current vs. time
j. Activate the high speed cameras or videos.
k. Actuate the PAB with the initiators deployed with the same delay as in the program’s 6 year old ATD
NHTSA1 low risk deployment test) with the minimum actuation current (1.2 A) at +23 °C.
l. Take still photographs of Module, Cover/Door, Cushion Assembly and Module Housing after test.
m. Test facility to complete post test documentation and retain indefinitely; Reference Appendix A.
Evaluation and Results. Module shall meet the functional requirements stated in GMW3109 “Module
Performance after Heat Aging“. Any feature for modifying or directing deployment energy for out-of-position
occupants shall exhibit intended functionality in video coverage recorded during the test. If intended
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functionality cannot be evaluated in video coverage, the responsible VEC may specify additional tests to
evaluate module performance. Module traceability bar code and label legibility shall meet the requirements
stated in GMW3109, “Label Legibility”.
3.2.1.17 DAB Module Emblem Deformation Resistance Test.
3.2.1.17.1 Purpose. To evaluate the DAB Module Emblem’s resistance to deformation.
This test is run on the DAB module alone, without the steering wheel.
3.2.1.17.2 Test Fixtures and Equipment.
Drop tube (see Figure 14).

Impactor (see Figure 15).
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3.2.1.17.3 Test Procedure.

e. 3.2.1.17.3.1 Condition Modules at +23 °C, as specified in paragraph 4.2, “Validation Plan”.
f. 3.2.1.17.3.2 Position DAB module on a rigid surface with the deployment surface up. If necessary, a rigid
block or jig shall be used to support the module so that it does not rest on the retaining pins, or any
component which would act as a spring or damper.
g. 3.2.1.17.3.3 Insert the pull-pin into the drop tube so the impactor will fall 450 mm onto the emblem.
h. 3.2.1.17.3.4 Insert the impactor into the drop tube so that the aluminum nose rests on top of the pull-pin.
i. 3.2.1.17.3.5 Position the drop tube so that it is centered on the DAB emblem, and touching the surface of
the DAB cover and/or emblem. If the emblem center is not the worst case for impact, then the VEC
engineer may specify another location.
j. 3.2.1.17.3.6 Quickly pull the pull-pin out of the drop tube. Allow the impactor to drop onto the emblem and
come to a rest before removing drop tube.
k. 3.2.1.17.3.7 Perform visual inspection of the module and emblem, and record observations. Any --```,``,`,,,`,``````,,-`-`,,`,,`,`,,`-
discrepancies noted shall be documented and reported to the Responsible VEC Engineer.
l. 3.2.1.17.3.8 Retain modules for inspection, and tear down or deployment as directed by the responsible
VEC Engineer.
3.2.1.17.4 Evaluation and Results. The DAB Module and emblem shall meet the deformation resistance
requirement stated in GMW3109, “Emblems on the Cover/Door”.
Figure 14: Drop Tube Construction
Pull Pin
530 mm Drop Tube
450 mm
Nom. ID = 52.5 mm
Hole D 25.4 mm
The drop tube shall be made of a rigid material with nominal ID of 52.5 mm (e.g. 2” Schedule 40 PVC pipe).
The holes for the pull-pin shall be drilled so that the top of the pull-pin is 450 mm from the bottom of the drop
tube. Another hole ≈ 25.4 mm diameter shall be drilled through the tube near the bottom.
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Figure 15: Impactor Construction
10 mm
~ 20 mm
D = 50.8 mm
Steel Ballast
Aluminum Nose R = 25.4 mm
The impactor shall consist of a semi-spherical aluminum nose, radius 25.4 mm, and steel ballast to make up
the required weight of 454 g (1 lb).
3.2.1.18 Push-in/Snap-in Attachment Insertion Effort Procedure.
3.2.1.18.1 Test Equipment.
Hand held palm force gage (optional Instron)

Steering wheel assembly with design intent Driver airbag
3.2.1.18.2 Procedure.
Apply load to one side of airbag module at a time. Either left hand/ right hand or top/ bottom. Record load
to fully engage snap in feature (visually inspect that locking feature is fully engaged).
Repeat for other side.
3.2.1.18.3 Evaluation and Results. The DAB insertion efforts shall meet the requirements in GMW3109
“Push-in/Snap-in Attachment Insertion/Removal Cycles and Forces”.
4 Validation
The System level validation testing is the responsibility of the responsible VEC Engineer. The Validation Test
Plan does not include developmental testing. Developmental test requirements are addressed in the SOR
document.
4.1 General. Samples of components or material released to this specification shall be tested for conformity
with the requirements of this specification and approved by the responsible VEC Department prior to
commencement of delivery of bulk supplies.
Any changes (e.g. design function, properties, manufacturing process and location of manufacture) make a
new release inevitable. It is the sole responsibility of the supplier to inform the customer unsolicited with a
documentation of all adjustments, modifications of parts and/or processes and to apply for a new release.
If not otherwise agreed the entire release test shall be repeated and documented by the supplier prior to
commencement of delivery of deviant bulk supplies. In single cases a shorter test can be agreed between the
responsible VEC Department and the supplier.
4.1.1 Inspection and Preparation. Before start of any test, the following steps shall be taken:
4.1.1.1 Document part number and serial number.
4.1.1.2 Perform visual, dimensional and weight inspection. Any discrepancies noted shall be documented and
reported to the responsible VEC Engineer.
4.1.1.3 Verify Module electrical resistance, shunt resistance (if applicable), and insulation resistance according
to paragraph 3.2.1.1.1, step f.
4.2 Validation Plan. This specification does not address developmental test requirements. It shall be the
responsibility of the supplier to identify and conduct a Development and Concept Validation Test Plan, as
defined in the program Statement of Requirements. Module Development Testing shall be completed prior to
start of DV testing.
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The supplier shall track all Module component failures observed in Development, DV or PV testing. The
supplier shall apply positive and specific irreversible corrective action for all Module component failures
observed during DV and PV.
The “Module Static Deployment Test” according to paragraph 3.2.1.1, shall be used for deployment
procedures. Alternate methods with demonstrated equivalency may be used only with written approval from
the Interior Center and the Subsystem Leadership Team.
The duration of Module conditioning shall be such that the core temperature of the Inflator within the Module
reaches and maintains the required conditioning temperature unless otherwise indicated. The Suppliers shall
provide data to the responsible VEC Engineer, indicating the time duration (t e) required for the Inflator's core
(within Module assembly) to reach and maintain the specified conditioning temperature. If the time duration (t e)
data is not provided, the minimum time for Module conditioning is 4 h. This statement applies to all
temperature conditioning and after approval test duration can be modified to (te) + 30 minutes.
Module static deployments shall be performed with the design intent attachments. Attachments shall meet
requirements stated in GMW3109 “Attachment”. If the door is part of the Module, it shall be included in all
testing listed in this document. If the door is not part of the module, then some tests are conducted with
doors/IPs/representative doors, and some without, as specified in the following test matrices. If a
representative PAB Door is specified, it shall simulate the production Door design and consist of the following
characteristics:
Approximate PAB Door size and shape

Approximate PAB Door mass
Approximate PAB Door tear seam design, size and shape
Approximate PAB Door breakout pressure: (1.7 to 2.4) bar ((25 to 35) psi)
Also the representative PAB Door shall be orientated to the Module per the following Key Interface of Design
(KIOD) drawings:
a. Interface of Module PAB Door
1. 40.702.01.03B.1 (Top +3/4 Mount PAB to Deployment Door
2. 40.702.01.03B.2 (Top +3/4 Mount PAB to Deployment Door)
3. 40.702.01.05.01B.2 (Top +3/4 Mount PAB hidden tear seam Deployment Door to IP)
4. 40.702.02.02B.1 (Mid Mount PAB to Deployment Door)
5. 40.702.02.02B.03 (Mid Mount PAB to Deployment Door)
b. Interface of Module to IP Attachment and IP Deployment Chute
1. 40.702.01.02B.1 (Top +3/4 Mount PAB Module to IP)
4. 40.702.01.01B.3 (Mid Mount PAB Module Orientation)
5. 40.702.02.01B.4 (Mid Mount PAB Module Orientation)
The responsible VEC Engineer shall be the final arbiter of door design level to be tested (Production
representative instrument panels are to be used as soon as they become available.
4.2.1 Design Validation (DV) Requirements. The Module DV shall begin with production intent design
Modules and shall meet General Motors Worldwide program timing. This Module DV shall not include
developmental testing. The DV process shall proceed according to the following sequence:
a. Supplier presents DFMEA/PFMEA and Fault Tree Analysis (FTA) to the responsible VEC Engineer for
review and approval.
b. Supplier submits DV Test Plan, configuration document, and timing to the responsible VEC Engineer for
review. The DV test plan shall contain but not be limited to a minimum set of tests and sample sizes in
accordance DV Matrix (paragraph 4.2.1.1 or 4.2.1.2), as well as additional testing requirements
recommended by the Supplier to address specific DFMEA/PFMEA issues.
c. The Module DV Test Plan shall be approved by the responsible VEC prior to implementation.
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d. DV build proceeds.
4.2.1.1 Module Design Validation Test Matrix. The test matrix shown in Tables 9 thru 12 is a set of tests and
quantity of sample sizes for validating Modules. It shall be the Supplier's responsibility to evaluate this plan and
identify any additional tests and/or larger sample sizes (at no additional cost) to validate the Module as
required, based on the VEC's decision for unique design requirements or to meet program specifics, as
defined in the SOR. The Module DV Test Plan shall be approved by the responsible VEC Engineer prior to
implementation.
Table 9: Single and Dual Stage Airbag Module-Level Design Validation "Lite" Test Matrix
DV Lite matrix applies to all modules that meet the following criteria:
1. c/o cover material
2. c/o housing material and geometry
3. c/o inflator family
c/o means : using surrogate data from full DV/PV exsisting modules to judge the applicability of DV Lite criteria
early I/Ps avai lable: IV M RD -18 weeks Single Stage Dual Stage
Deployment Condition (°C)
# Deployment Condition (°C) Not # High Level Low Level Not

Modules deployed Modules deployd
+23 +85 +23 +85
AB DV Complete by: IV GA MRD Paragr.: -30 +23 +85 -30 -30
Baseline Tests: 3.2.1.1.1 12 5 2 5 22 5 2 5 5 2 3
Note 2
Se que ntial Te sts : 3.2.1.2
Dynamic Shock (High G | Low G), 3.2.1.2.1 7 6 10 9
Vibration/Temp, 3.2.1.2.2 13 19
Service Durability, 3.2.1.2.6 13 19
Deploym ent: (High G | Low G) 12 18
3.2.1.2.8 3 3 3 3 1 0 2 3 3 2 2 1 2 3 1 0
Heat Ageing, Low Hum idity Test: 3.2.1.3.1 12 4 4 4 24 4 4 4 4 4 4
Effluent Test: 3.2.1.6 3 3 6 3 3
Module Integrity: 3.2.1.15 3 3 3 3
Total Modules: 43 15 9 18 1 74 14 9 17 14 9 12 1
Visible Door/Class A
Cover M odule Tests: Note 1, Note 3 # Modules -30 +23 +85 Not deployd # Modules -30 +23 +85 -30 +23 +85 Not deployd
Solar Exposure Test (per color, test all colors) 3.2.1.7 2 2 2 2

Hand Impact Test 3.2.1.12 3 3 3 3
Total w ith Visible Door/Class A Cover: 5 0 0 0 5 5 0 0 0 0 0 0 5
DAB Module & Horn Tests: # Modules -30 +23 +85 Not deployd # Modules -30 +23 +85 -30 +23 +85 Not deployd
DAB Horn Durability 3.2.1.11.1 3 3 3 3

DAB Horn Effort 3.2.1.11.3 3 3 3 3
DAB Emblem Impact Test 3.2.1.17 3 3 3 3
Total DAB & Horn specific tests: 9 9 9 0 0 0 0 0 0 9
Note 1: These tests are only required for modules with discrete doors.
Note 2: In sequential tests, the modules are run through each type of conditioning in order. For the dynamic shock conditioning, half the
modules plus the extra one are run at (and marked) High G, the remaining modules are run at (and marked) Low G. All of the modules are
then run through the next 3 types of conditioning.
Then the modules are deployed as shown. The numbers of High G / Low G modules in each cell are separated with a slash, e.g. 2/3.
Note 3: These test groups may need to be repeated. The quantity in the table is the minimum quantity for one repeat. The solar exposure
test shall be repeated for each color.
Only need to run if paint supplier (process), substrate material, color and paint/material resin have not been previously tested. Solar testing
must be complete by VTC.
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Table 10: Single and Dual Stage DAB, PAB and KAB Design Validation Test Matrix
Notes:
PAB-IP: A PAB that deploys through the IP (door-on-IP) is deployed with development IPs (or IVER IPs if available), and without door/IP as shown below. The PAB modules
are conditioned, the doors/IPs are not. Development (or pre-IVER) IPs may be half or whole, as available.
Single Stage Dual Stage LRD

Tim ing: Deployment Condition (°C)
BODY
BLOCK
Development IPs available: IV MRD - 18 weeks # Deployment Condition (°C) Not # High Level Low Level Not
AB DV Complete by: IV GA MRD Modules deploy Modules deploy
Paragr.: -30 +23 +85 -30 +23 +85 -30 +23 +85 3.2.1.16
Baseline Te sts: 3.2.1.1.1 12 5 2 5 22 5 2 5 5 2 3 2

12 5 2 5 22 5 2 5 5 2 3
If PAB-IP, deploy without door/IP 3.2.1.1.1
Seque ntial Tests : Note 2 3.2.1.2 13 19
Dynamic Shock (High G | Low G)
3.2.1.2.1 7 6 10 9 1:1
Vibration/Temp 3.2.1.2.2 13 19
Thermal Shock 3.2.1.2.3 13 19
Humidity Resistance 3.2.1.2.4 13 19
Salt Spray 3.2.1.2.5 13 19
Service Durability 3.2.1.2.6 13 19
Squeak, Rattle & Noise Avoidance 3.2.1.2.7 3 3 1 2 2 1 3 3 1 1 1 1 0 1 1 0
Deployme nt: (High G | Low G) 3.2.1.2.8 12 3 3 3 3 1 0 19 2 3 3 2 2 1 2 3 1 1:1
If PAB-IP, deploy without door/IP 3.2.1.2.8 12 3 3 3 3 1 0 19 2 3 3 2 2 1 2 3 1
Heat Ageing, Low Humidity Test: 3.2.1.3.1 12 4 4 4 24 4 4 4 4 4 4 2
If PAB-IP, deploy with development/pre-IVER half IP 3.2.1.3.1 6 2 2 2 9 2 2 2 2 1
If PAB-IP, deploy without door/IP 3.2.1.3.1 6 2 2 2 15 2 2 2 2 4 3
Heat Ageing, High Humidity Test: 3.2.1.3.3 6 2 2 2 10 2 2 2 2 2 2
If PAB-IP, deploy without door/IP 3.2.1.3.3 6 2 2 2 10 2 2 2 2 2
CE conform ity (supplie r responsible) 3.2.1.4 3 3 3
Drop Test: 2.5 Meter Drop 3.2.1.5 1 1 1 1
Drop Test: 1.2 Meter Drop 3.2.1.5 3 3 4 2 2
Effluent Test: 3.2.1.6 3 3 6 3 3
Ozone (Elas tome ric Only) 3.2.1.8 3 3 4 2 2
Module Electrical Stress Tes t 3.2.1.9 3 3 3 3
Module Integrity: 3.2.1.15 3 3 3 3
If PAB-IP, deploy without door/IP 3.2.1.15 3 3 3 3
Total Modules: 62 17 17 20 8 96 16 15 19 14 13 14 5 8
# Developme nt /IVER IPs required for PAB: 6 2 2 2 0 9 2 2 2 2 0 1 0
Note 1, Note 3
Visible Door/Class A Cover Module Tests: # Modules -30 +23 +85 Not deploy # Modules -30 +23 +85 -30 +23 +85 Not deploy

Module Fatigue Test 3.2.1.10 3 3 3 3
Finger Indentation Test 3.2.1.13 3 3 3 3
Pry Resistance Test, PAB/SIAB Only 3.2.1.14 3 3 3 3
Total w ith Visible Door/Class A Cove r: 14 0 0 0 14 14 0 0 0 0 0 0 14
DAB Module & Horn Tests : # Modules -30 +23 +85 Not deploy # Modules -30 +23 +85 -30 +23 +85 Not deploy

DAB Horn Sensitivity 3.2.1.11.2 3 3 3 3
DAB Horn Eff ort 3.2.1.11.3 3 3 3 3
Total DAB & Horn specific te sts: 12 0 0 0 12 12 0 0 0 0 0 0 12
Note 2: In sequential tests, the modules are run through each type of conditioning in the order given. For the dynamic shock conditioning,
half the modules plus the extra one are run at (and marked) High G, the remaining modules are run at (and marked) Low G. Then the
modules are deployed as shown. The numbers of High G / Low G modules in each cell are separated with a slash, e.g. 2/3.
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Table 11: Dual Depth/ Active vent Airbag Module-Level Design Validation Test Matrix "LITE"
Notes:
Deployment Conditions:
P = Deploy the dual depth mechanism at the most frequent deep-cushion deploy time, as determined by the occupant performance group.
I = Deploy the dual depth mechanism 1 ms before maxim um inflator slope.
N = Do not deploy the dual depth mechanism.
D = Deploy the dual depth mechanism to dispose of the mechanism initiator at the program 's disposal deployment delay time.
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PAB-IP: A PAB that deploys through the IP (door-on-IP) is deployed with development IPs (or IVER IPs if available), and without door/IP as shown below. The PAB modules
are conditioned, the doors/IPs are not. Development (or pre-IVER) IPs may be half or whole, as available.
Timing: Deployment Condition (°C)

Development IPs available: IV MRD - 18 weeks # Deep & P Deep & I Shallow & N Shallow & D No t
AB DV Complete by: IV GA MRD Modules
-30 deploy
Paragr.: -30 +23 +85 -30 +23 +85 +23 +85 -30 +23 +85
Baseline deployments 3.2.1.1.1 22 2 2 2 3 3 4 2 2 1 1
Sequential Tests: 3.2.1.2

Dynamic Shock (High G | Low G),
RRAB/PAB/KAB Only
3.2.1.2.1 10 9
Vibration/Temp, RRAB/PAB/KAB Only 3.2.1.2.2 19
Service Durability, DAB Only 3.2.1.2.6 19
Deployment: (High G | Low G) 3.2.1.2.8 19 1 1 1 1 2 1 1 2 1 1 1 2 1 0 1 1 1 0
If PAB-IP, deploy without door/IP 3.2.1.2.8 19 1 1 1 1 2 1 1 2 1 1 1 2 1 0 1 1 1 0
Heat Ageing, Low Humidity Test: 3.2.1.3.1 24 2 2 2 2 2 2 3 2 2 1 2 2
If PAB-IP, deploy
with development /pre-IVER half IP
3.2.1.3.1 9 2 2 2 2 1
Effluent Test: module 3.2.1.6 6 3 3
Module Integrity: 3.2.1.15 2 1 1
If PAB-IP, deploy without door/IP 3.2.1.15 2 1 1
Total Modules: 73 6 7 7 8 2 8 9 4 8 3 5 5 1
# Development /IVER IPs required for PAB: 9 2 2 2 0 0 0 2 0 1 0 0 0 0
Visible Door/Class A Cover Module Tests: # Modules -30 +23 +85 -30 +23 +85 -30 +23 +85 -30 +23 +85 Not deployd
Solar Exposure Test (per color, test all colors) 3.2.1.7 2 2

Hand Impact Test 3.2.1.12 3 3
Total with Visible Door/Class A Cover: 5 0 0 0 0 0 0 0 0 0 0 0 0 5
DAB Module & Horn Tests: # Modules -30 +23 +85 -30 +23 +85 -30 +23 +85 -30 +23 +85 Not deployd
DAB Horn Durability 3.2.1.11.1 3 3

DAB Horn Effort 3.2.1.11.3 3 3
DAB Emblem Impact Test 3.2.1.17 3 3
Total DAB & Horn specific tests: 9 0 0 0 0 0 0 0 0 0 0 0 0 9
test shall repeated for each color.
shall be complete by VTC.
GM Confidential
Table 12: Dual Depth /Active Vent Airbag Module-Level Extended Design Validation Test Matrix
Notes :
Deployment Conditions:
P = Deploy the dual depth mechanism at the most frequent deep-cushion deploy time, as determine d by the occupant performance group.
I = Deploy the dual depth mechanism 1 ms before maximum inflator slope .
N = Do not de ploy the dual depth mechanism.
D = Deploy the dual depth mechanis m to dispose of the mechanis m initiator at the program's disposal deployment delay time.
PAB-IP: A PAB that deploys through the IP (door-on-IP) is deployed with development IPs (or IVER IPs if available), and without door/IP as shown below. The PAB modules are
conditioned, the doors/IPs are not. . Development (or pre-IVER) IPs may be half or whole, as available.
Tim ing: Deployment Condition (°C)

Development IPs available: IV MRD - 18 weeks # Deep & P Deep & I Shallow & D Shallow & D Not
AB DV Complete by: IV GA MRD deploy
Modules -30 +23 +85 -30 +23 +85 -30 +23 +85 -30 +23 +85
Paragr.:
Bas eline Tes ts : 3.2.1.1.1 22 2 2 2 3 3 4 2 2 1 1 0
Seque ntial Tes ts : 3.2.1.2
Dynamic Shock (High G | Low G) 3.2.1.2.1 10 9
Vibration/Temp 3.2.1.2.2 19
Thermal Shock 3.2.1.2.3 19
Humidity Resistance 3.2.1.2.4 19
Salt Spray 3.2.1.2.5 19
Service Durability 3.2.1.2.6 19
Squeak, Rattle & Noise Avoidance (High G | Low G) 3.2.1.2.7 3 3
De ploym ent: (High G | Low G) 3.2.1.2.8 19 1 1 1 1 2 1 1 2 1 1 1 2 1 1 1 1
Heat Age ing, Low Hum idity Test: 3.2.1.3.1 24 2 2 2 2 2 2 3 2 2 1 2 2
If PAB-IP, deploy with development/pre-IVER half IP 3.2.1.3.1 9 2 2 2 2 1
Heat Age ing, High Hum idity Test: 3.2.1.3.3 10 2 2 2 2 2
If PAB-IP, deploy without door/IP 3.2.1.3.3 2 2 2 2 2
10
CE Conform ity (s upplie r respons ible ) 3.2.1.4 3 3
Drop Te st: 2.5 Meter Drop 3.2.1.5 1 1
Drop Te st: 1.2 Meter Drop 3.2.1.5 4 2 2
Effluent Test: 3.2.1.6 6 3 3
Ozone (Elastom eric ONLY) 3.2.1.8 4 2 2
Module Electrical Stress Test 3.2.1.9 3 3
Total Modules: 98 6 9 7 10 6 10 9 4 8 10 4 7 8
# Developm ent /IVER IPs required for PAB: 9 2 2 2 0 0 0 2 0 1 0 0 0 0
Visible Door/Class A Cover Module Tests: # Modules -30 +23 +85 -30 +23 +85 -30 +23 +85 -30 +23 +85 Not deploy

Module Fatigue Test 3.2.1.10 3 3
Hand Impact Test
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3.2.1.12 3 3
Finger Indentation Test 3.2.1.13 3 3
Pry Resistance Test, PAB/SIAB Only 3.2.1.14 3 3
Total w ith Visible Door/Class A Cove r: 14 0 0 0 0 0 0 0 0 0 0 0 0 14
DAB Module & Horn Tests: # Modules -30 +23 +85 -30 +23 +85 -30 +23 +85 -30 +23 +85 Not deploy

DAB Horn Sensitivity 3.2.1.11.2 3 3
DAB Horn Ef fort 3.2.1.11.3 3 3
Total DAB & Horn specific tests: 12 0 0 0 0 0 0 0 0 0 0 0 0 12
GM Confidential
4.2.1.2 PAB and KAB System Level DV Test Matrix. The test matrix shown in Table 13 is a set of tests and
quantity of sample sizes for validating a Passenger or Knee Airbag System. Reference procedure in
paragraph 3.2.1.2. This test matrix shall be repeated for each unique IP the AB will be used in. The AB and IP
suppliers shall be expected to provide required test hardware, as defined in the SOR. However, if the
PAB/KAB System is fully integrated and sourced to a single Tier 1 supplier, (IP and PAB/KAB sourced to a
single Tier 1 supplier) then the Tier 1 supplier shall be responsible for System Level Testing and execution of
DV Test Matrix. The PAB/KAB System DV Test Matrix shall be approved by the responsible VEC Engineer
prior to implementation. At completion of DV Testing, if IP material changes are needed, the IP supplier shall
be required to receive approval from the responsible VEC prior to any material changes.
Table 13: PAB and KAB Airbag and Deployment Door System Level Design Validation Test Matrix
System Deployment Condition (°C)

Timing:
Single Stage, High Level Low Level
No. of or Deep and P or Shallow and N
System DV End: IV MRD – 6 weeks modules
-30 +23 +75 -30 +23 +75
Single Stage:
Baseline Tests: With IP 8 3 2 3 n/a n/a n/a
Heat Age-Low Humidity: With IP 8 4 0 4 n/a n/a n/a
Totals: 16 7 2 7 n/a n/a n/a
Dual Stage: (High Level/Low Level)
Baseline Tests: With IP 12 2 2 2 2 2 2
Heat Age-Low Humidity: With IP 8 2 0 2 2 0 2
Totals: 20 4 2 4 4 2 4
Dual Depth:
(Deep and P/Shallow and N)
Totals: 20 4 2 4 4 2 4
Key:
P = For Dual Depth Airbags: deploy the dual depth mechanism at the most frequent deployment time for the
deep cushion as determined by the program’s occupant performance group.
N = For Dual Depth Airbags: do not deploy the dual depth mechanism.
Note: These System tests shall be run by the IP supplier, using Integration Vehicle IPs. For the Heat-Aged
tests, the Airbag modules are unaged, and the IPs are aged according to paragraph 3.2.1.3.1 item b. For the
Baseline tests use unaged parts.
System level deployments shall be scheduled such that deployments shall begin as soon as possible, (not to
exceed 2 weeks) upon completion of Heat Age conditioning.
If a discrete Airbag-mounted door (door-on-module) is used, then the system level DV and PV tests shall be
reduced in quantity to one test per condition since the Airbag mounted door has already been validated in
component level tests.
At the discretion of the responsible VEC, if the Deployment Door/Instrument Panel material selection is thought
to be susceptible to extreme humidity as well as temperature, this matrix may be adjusted accordingly to
ensure worst case validation requirements are tested.
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4.2.2 Product Process Validation (PV) Requirements. PV shall begin with production design Modules that
have met design validation requirements, and manufactured with production intent tools, materials and
processes. Module PV shall meet GMW program timing. The Module PV shall not include any developmental
or design validation testing. The PV Test Plan shall be structured in according to paragraphs 4.2.2.1 and
4.2.2.2 of this document (PV Test Matrix) with two non-consecutive lots of Modules and IPs (where required).
The Module Cover/Door assemblies shall be included from all production cavities and tools. This shall be the
minimum set of tests and sample sizes for Module PV with production intent design, tooling, materials and
production processing. The Module PV Test Plan shall be approved by the Responsible VEC Engineer prior to
implementation.
Note: For any post PV evaluations of critical interfaces that are defined and agreed to by the validation TIE
and DRE, test quantity of 19 parts to be tested without failure and temperature that aggravates condition.
(Quantity derived by using Binomial distribution with a 95 % probability of detection.) This shall not be
superseded by margin testing.
4.2.2.1 Module Process Validation Test Matrix. The test matrix shown in Tables 14 and 15 are a set of tests
and quantities of sample sizes for validating Modules. It shall be the Supplier's responsibility to evaluate this
plan and identify any additional tests and/or larger sample sizes (at no additional cost) to validate the Module
as required, based on the VEC's decision for unique design requirements or to meet program specifics, as
defined in the SOR. The Module PV Test Plan shall be approved by the responsible VEC Engineer prior to
implementation.
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Table 14: Single and Dual Stage DAB, PAB and KAB Process Validation Test Matrix
Notes:
PAB-IP: A PAB that deploys through the IP (door-on-IP) is deployed with development IPs (or IVER IPs if available), and without door/IP as shown below. The PAB
modules are conditioned, the doors/IPs are not. . Development (or pre-IVER) IPs may be half or whole, as available.
Single Stage Dual Stage LRD

B ODY
Development IPs available: IV MRD - 18 weeks # Deployment Condition (°C) Low Level BLOCK
Not # High Level Not
AB DV Complete by: IV GA MRD Modules deploy Modules -30 +23 +85 -30 +23 +85 deploy
Paragr.: -30 +23 +85 3.2.1.16
Baseline Tests: 3.2.1.1.1 12 5 2 5 22 5 2 5 5 2 3 2

12 5 2 5 22 5 2 5 5 2 3
If PAB-IP, deploy without door/IP 3.2.1.1.1
Sequential Tests: Note 2 3.2.1.2 13 19
Dynamic Shock (High G | Low G)
3.2.1.2.1 7 6 10 9 1:1
Vibration/Temp 3.2.1.2.2 13 19
Thermal Shock 3.2.1.2.3 13 19
Humidity Resistance 3.2.1.2.4 13 19
Salt Spray 3.2.1.2.5 13 19
Service Durability 3.2.1.2.6 13 19
Squeak, Rattle & Noise Avoidance 3. 2.1 .2. 7 3 3 1 2 2 1 3 3 1 1 1 1 0 1 1 0
Deployment: (High G | Low G) 3.2.1.2.8 12 3 3 3 3 1 0 19 2 3 3 2 2 1 2 3 1 1:1
Heat Ageing, Low Humidity Test: 3.2.1.3.1 12 4 4 4 24 4 4 4 4 4 4 2
Heat Ageing, High Humidity Test: 3.2.1.3.3 6 2 2 2 10 2 2 2 2 2 2
CE conformity (supplier responsible)

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Drop Test: 2.5 Meter Drop 3.2.1.5 2 2 2 2
Drop Test: 1.2 Meter Drop 3.2.1.5 4 4 8 4 4
Effluent Test: 3.2.1.6 4 4 4 2 2
Ozone (Elastomeric Only) 3.2.1.8 4 4 4 2 2
Module Electrical Stress Test 3.2.1.9 4 4 4 4
Module Inte grity: 3.2.1.15 4 4 4 4
If PAB-IP, deploy without door/IP 3.2.1.15 4 4 4 4
Total Modules: 69 17 20 21 11 101 16 16 20 14 14 14 7 8
Visible Door/Class A Cover Module Tests: Note 1, Note 3 # Modules -30 +23 +85 Not deploy # Modules -30 +23 +85 -30 +23 +85 Not deploy

Module Fatigue Test 3.2.1.10 4 4 4 4
Finger Indentation Test 3.2.1.13 4 4 4 4
Pry Resistance Test, PAB/SIAB Only 3.2.1.14 4 4 4 4
Total with Visible Door/Class A Cover: 18 0 0 0 18 18 0 0 0 0 0 0 18
DAB Module & Horn Tests: # Modules -30 +23 +85 Not deploy # Modules -30 +23 +85 -30 +23 +85 Not deploy

DAB Horn Sensitivity 3.2.1.11.2 4 4 4 4
DAB Horn Ef fort 3.2.1.11.3 4 4 4 4
Total DAB & Horn specific tests: 16 0 0 0 16 16 0 0 0 0 0 0 16
Only need to run if paint supplier (process), substrate material, color & paint/material resin have not been previously tested. Solar testing
GM Confidential
Table 15: Dual Depth PAB Process Validation Test Matrix

Notes :
Deployment Conditions :
P = Deploy the dual depth mechanism at the most frequent deep-cushion deploy time, as determine d by the occupant performance group.
I = Deploy the dual depth mechanism 1 ms before maxim um inflator slope .
N = Do not de ploy the dual depth mechanism .
D = Deploy the dual depth mechanism to dis pose of the mechanism initiator at the program's disposal deployment delay time.
PAB-IP: A PAB that deploys through the IP (door-on-IP) is deployed with development IPs (or IVER IPs if available), and without door/IP as shown below. The PAB modules are
conditioned, the doors/IPs are not. Development (or pre-IVER) IPs may be half or whole, as available.

Development IPs available: IV MRD - 18 weeks # Deep & P Deep & I Shallow & D Shallow & D Not
AB DV Complete by: IV GA MRD Modules deploy
Section: -30 +23 +85 -30 +23 +85 -30 +23 +85 -30 +23 +85
Baseline Tests: 3.2.1 22 2 2 2 3 3 3 2 2 2 1 0
If PAB-IP, deploy without door/IP 3.2.1 22 2 2 2 3 3 3 2 2 2 1
Sequential Tests: 3.2.1.2

Dynamic Shock (High G | Low G) 3.2.1.2.1 10 9
Vibration/Temp
3.2.1.2.2 19
Thermal Shock 3.2.1.2.3 19
Humidity Resistance 3.2.1.2.4 19
Salt Spray 3.2.1.2.5 19
Service Durability 3.2.1.2.6 19
Squeak, Rattle & Noise Avoidance (High G | Low G) 3.2.1.2.7 3 3 1 0 0 1 1 0 0 1 1 0 0 1
Deploym ent: (High G | Low G) 3.2.1.2.8 19 1 1 1 1 2 1 1 2 1 1 1 2 1 1 1 1
Heat Ageing, Low Hum idity Te st: 3.2.1.3.1 24 2 2 2 2 2 2 3 2 2 1 2 2

Heat Ageing, High Hum idity Te st: 3.2.1.3.3 10 2 2 2 2 2
If PAB-IP, deploy without door/IP 3.2.1.3.3 10 2 2 2 2 2
CE Conform ity (supplier responsible) 3.2.1.4 4
Drop Te st: 2.5 Meter Drop 3.2.1.5 2 2
Drop Te st: 1.2 Meter Drop 3.2.1.5 8 4 4
Efflue nt Te st: 3.2.1.6 4 2 2
Ozone (Elastom eric Only) 3.2.1.8 4 2 2
Module Electrical Stress Te st 3.2.1.9 4 4
Total Module s: 101 6 10 8 10 6 10 8 4 9 12 4 7 7
Visible Door/Class A Cover Module Te sts: # Modules -30 +23 +85 -30 +23 +85 -30 +23 +85 -30 +23 +85 Not deploy

Module Fatigue Test 3.2.1.10 4 4
Hand Impact Test 3.2.1.12 4 4
Finger Indentation Test 3.2.1.13 4 4
Pry Resistance Test, PAB/SIAB Only 3.2.1.14 4 4
Total w ith Visible Door/Class A Cover: 18 0 0 0 0 0 0 0 0 0 0 0 0 18
DAB Module & Horn Te sts: # Modules -30 +23 +85 -30 +23 +85 -30 +23 +85 -30 +23 +85 Not deploy

DAB Horn Sensitivity 3.2.1.11.2 4 4
DAB Horn Ef fort 3.2.1.11.3 4 4
Total DAB & Horn s pe cific tests: 16 0 0 0 0 0 0 0 0 0 0 0 0 16
Note 1: These tests are only required for modules with discrete doors. --```,``,`,,,`,``````,,-`-`,,`,,`,`,,`---
Only need to run if paint supplier (process), substrate material, color & paint/material resin have not been previously tested. Solar testing
GM Confidential
4.2.2.2 PAB and KAB System Level PV Test Matrix. The test matrix shown in Table 16 is a set of tests and
quantity of sample sizes for validating a Passenger or Knee Airbag System. Reference test procedure in
paragraph 3.2.1.2. This test matrix shall be repeated for each unique IP the AB will be used in. The AB and IP
suppliers shall be expected to provide required test hardware, as defined in the SOR. However, if the
PAB/KAB System is fully integrated and sourced to a single Tier 1 supplier, (IP and PAB/KAB sourced to same
Tier 1 supplier) then the Tier 1 supplier shall be responsible for System Level Testing and execution of PV Test
Matrix. The PAB/KAB System PV Test Matrix shall be approved by the responsible VEC Engineer prior to
implementation.
Table 16: PAB and KAB Module and Deployment Door System Level Process Validation Test Matrix
System Deployment Condition (°C)

Timing: No. of Single Stage, High Level Low Level
System PV End: VTC – 6 weeks modules or Deep and P or Shallow and N
-30 +23 +75 -30 +23 +75
Single Stage:
Baseline Tests: With IP 8 3 2 3 n/a n/a n/a
Heat Age-Low Humidity: With IP 8 4 0 4 n/a n/a n/a
Totals: 16 7 2 7 n/a n/a n/a
Dual Stage: (High Level/Low Level)
Baseline Tests: With IP 12 2 2 2 2 2 2 --```,``,`,,,`,``````,,-`-`,,`,,`,`,,`---
Totals: 20 4 2 4 4 2 4
Dual Depth:
(Deep and P/Shallow and and N)
Totals: 20 4 2 4 4 2 4
Key:
P = For Dual Depth Airbags: deploy the dual depth mechanism at the most frequent deployment time for the
deep cushion as determined by the program’s occupant performance group.
N = For Dual Depth Airbags: do not deploy the dual depth mechanism.
Note: These System tests shall be run by the IP supplier, using Production IPs. For the Heat-Aged tests, the
Airbag modules are unaged, and the IPs are aged according to paragraph 3.2.1.3.1, item b. For the Baseline
tests use unaged parts.
System level deployments shall be scheduled such that deployments shall begin as soon as possible, (not to
exceed 2 weeks) upon completion of Heat Age conditioning.
If a discrete Airbag-mounted door (door-on-module) is used, then the system level DV and PV tests shall be
reduced in quantity to one test per condition since the Airbag mounted door has already been validated in
component level tests.
At the discretion of the Responsible VEC(s), if the Deployment Door/Instrument Panel material selection is
thought to be susceptible to extreme humidity as well as temperature, this matrix may be adjusted accordingly
to ensure worst case validation requirements are tested.
4.2.3 Dual Depth Mechanism/Active Vent Subcomponent Validation Requirements. These tests are
required for Modules with Dual Depth Mechanisms only.
GM Confidential
4.2.3.1 Dual Depth Mechanism/Active vent Subcomponent DV Test Matrix.

Note: These tests shall be successfully completed prior to the start of Module Level DV testing.)
The test matrix shown in Table 17 is a set of tests and quantity of sample sizes for design validating the Dual
Depth Mechanism /Active vent Subcomponent. It shall be the Supplier's responsibility to evaluate this plan and
identify any additional tests and/or larger sample sizes (at no additional cost) to validate the Dual Depth
Mechanism/Active vent Subcomponent as required, based on the VEC's decision for unique design
requirements or to meet program specifics, as defined in the SOR. The Dual Depth Mechanism/Active vent
Subcomponent DV Test Plan shall be approved by the Responsible VEC Engineer prior to implementation.
The responsible VECs shall define representative deployment door requirements for this test matrix.
Table 14: Dual Depth Mechanism/Active Vent Subcomponent DV Test Matrix
Timing: Conduct These Tests Prior to Starting the Airbag Module Level DV, paragraph 4.2.1.1
Temperature Number Test Type Hardware Setup Test Conditions Functional

Requirement
+85 °C 6 static Dual depth Deploy mechanism at Mechanism shall

deployment mechanism in time of max. inflator function as intended and
production intent slope and with max. maintain its structural
module housing with static tether loads Note 1 integrity at hot temp.
production intent applied.
inflator and static
tether loads applied
+23 °C 2 static Dual depth Deploy mechanism at Mechanism shall

module housing with static tether loads1 integrity at ambient
production intent applied. temp.
inflator and static
-30 °C 6 static Dual depth Deploy mechanism at Mechanism shall

module housing with static tether loads Note 1 integrity at cold temp.
production intent applied
inflator and static
+85 °C 10 static Dual depth Use production-intent Mechanism shall

deployment mechanism in dual depth mechanism function as intended and
production intent igniter uploaded to the maintain its structural
module housing with max tolerance level. integrity in a disposal
predeployed or inert Deploy in chamber, at deployment under worst
production intent temperature with zero case (hot) conditions.
inflator tether loads.
+85 C 10 static Dual depth Use production-intent Structural integrity of the

deployment mechanism in dual depth mechanism mechanism and its
production intent igniter uploaded to the mounting shall be
module housing with max tolerance level. maintained under worst
predeployed or inert Deploy in chamber, at case tolerance stackup
production intent temperature with piston conditions.
inflator locked in undeployed
position.
Note 1: Maximum tether loads shall be measured and quantified in development tests prior to the start of this subcomponent DV validation
series.
GM Confidential
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4.2.3.2 Dual Depth Mechanism/Active Vent PV Subcomponent Test Matrix.

Note:
a. Timing: These tests shall be successfully completed prior to the start of Module Level PV testing.
b. If there are no major changes to the Dual Depth Mechanism Subcomponent between DV and PV testing,
then these tests may be run in DV only and not in PV, with VEC approval.
The test matrix shown in Table 18 is a set of tests and quantity of sample sizes for process validating the Dual
Depth Mechanism/Active vent Subcomponent. It shall be the Supplier's responsibility to evaluate this plan and
identify any additional tests and/or larger sample sizes (at no additional cost) to validate the Dual Depth
Mechanism/Active vent Subcomponent as required, based on the VEC's decision for unique design
requirements or to meet program specifics, as defined in the SOR. The Dual Depth Mechanism/Active vent
Subcomponent PV Test Plan shall be approved by the Responsible VEC Engineer prior to implementation.
The responsible VEC shall define representative deployment door requirements for this test matrix.
Table 18: Dual Depth Mechanism/Active vent Subcomponent PV Test Matrix
Timing: Conduct These Tests Prior to Starting the Airbag Module Level PV, paragraph 4.2.2.1
Temp. No. Test Type Hardware Setup Test Conditions Functional Requirement
+85 °C 8 static Dual depth mechanism in Deploy mechanism at time Mechanism shall function
deployment production intent module of max. inflator slope and as intended and maintain
housing with production with max. static tether its structural integrity at hot
intent inflator and static loads Note 1 applied. temp.
+23 °C 4 static Dual depth mechanism in Deploy mechanism at time Mechanism shall function
housing with production with max. static tether its structural integrity at
intent inflator and static loads Note 1 applied. ambient temp.
-30 °C 8 static Dual depth mechanism in Deploy mechanism at time Mechanism shall function
housing with production with max. static tether its structural integrity at
intent inflator and static loads Note 1 applied cold temp.
+85 °C 20 static Dual depth mechanism in Use production-intent dual Mechanism shall function
deployment production intent module depth mechanism igniter as intended and maintain
housing with predeployed uploaded to the max its structural integrity in a
or inert production intent tolerance level. Deploy in disposal deployment under
inflator chamber, at temperature worst case (hot)
with zero tether loads. conditions.
+85 °C 20 static Dual depth mechanism in Use production-intent dual Structural integrity of the
deployment production intent module depth mechanism igniter mechanism and its
housing with predeployed uploaded to the max mounting shall be
or inert production intent tolerance level. Deploy in maintained under worst
inflator chamber, at temperature case tolerance stackup
with piston locked in conditions.
undeployed position.
Note 1: Maximum tether loads shall be measured and quantified in development tests prior to the start of this subcomponent DV validation
series.
4.3 Supporting Paragraphs.

4.3.1 Product Audit Requirements. The supplier shall develop a Lot Acceptance Testing (LAT) Plan based
on their documented product/process capabilities. In addition to the LAT plan from GSSLT (CG3378). The Plan
shall be approved by the Responsible VEC Engineer and shall be part of the PPAP documentation package.
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Any and all changes in production tools, production process, Module design or material and subsuppliers shall
be subject to the GM change management process and shall be approved by the Responsible VEC Engineer
prior to implementation. Module revalidation may be required depending on the extent of the proposed change.
GM shall be the final arbiter on whether revalidation shall occur. Written EWO approval by the Responsible
VEC Engineer is required before any change implementation.
5 Provisions for Shipping

The Module shipping requirements and guidelines shall be defined in the Program Specific Statement of
Requirements (SOR) document.
6 Notes
6.1 Glossary.
Airbag: Same as Module. In this document, airbag does not refer to a single component, i.e. the cushion.
Airbag System: A subsystem consisting of the Module, any other airbag Modules (e.g. side impact airbag or
roof rail airbag), sensing and diagnostic devices, energy reserve devices, and attachment wires.
Cushion: The bag, which is filled with gases when the inflator ignites.
Frontal Airbag Modules: See Module definition.
Inflator: An inflator is a device, which generates gas and initiates the gas generation.
Initiator: An initiator is a device which initiates gas generation by converting electrical energy into heat.
Low Risk Deployment (LRD): A PAB where FMVSS 208 compliance is being achieved via Low Risk
Deployment for the six year old ATD, and optionally for the three year old ATD.
Module: A component consisting of an inflator, a cushion, a housing, and/or a cover/door. In this document
Module references Frontal Airbag Module, which includes the Driver Airbag Module , the Passenger Airbag
Module,and the Knee Airbag Module (s).
Push-In Attachment: A push-in attachment is a fastener that does not mechanically latch into position when
inserted into its receptacle.
Reliability: Performance over life.
Shall: In this document shall denotes a binding provision that must be met unless a deviation is granted by the
responsible VECs.
Should: In this document, should denotes a preference, or desired conformance that must be tested and, if
not met, shall be documented and disclosed by the Supplier and approved by the responsible VECs. Should
requirements must be met unless non-compliance has been approved by the responsible VECs.
Snap-In Attachment: A snap-in attachment is a fastener that mechanically latches into position when inserted
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into its receptacle.

VEC: Vehicle Engineering Center. Refers to the GM Worldwide entity assigned to designing and developing a
vehicle.
6.2 Acronyms, Abbreviations, and Symbols.
ABAirbag
ATDAnthropometric Test Device
BAMBundesanstalt für Materialprüfung
B-I-WBody In White
CEConformité Européene
CMVSSCanadian Motor Vehicle Safety Standards
DABDriver Airbag Module
DFMEADesign Failure Mode and Effects Analysis
DKABDriver Knee Airbag Module
DOTDepartment of Transportation
DVDesign Validation
GM Confidential
EMC ElectroMagnetic Compatibility

FMEA Failure Mode and Effects Analysis
FMVSS Federal Motor Safety Standards (USA)
FTA Fault Tree Analysis
GMIO General Motors International Operations
GMNA General Motors North America
GMP General Motors Plastic
GMW General Motors Worldwide
IP Instrument Panel
ISO International Organization of Standards
KAB Knee Airbag Module
KIOD Key Interface of Design
N/A Not Applicable
PAB Passenger Airbag Module
PFMEA Process Failure Mode and Effects Analysis
PKAB Passenger Knee Airbag
PN Part Number
ppm part per million
PV Process/Production Validation
RH Relative Humidity
SAE SAE International
SOR Statement of Requirements
TWA Time Weighted Average
UV Ultraviolet
VDC Volts Direct Current
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7 Additional Paragraphs
7.1 All parts or systems supplied to this standard must comply with the requirements of GMW3059, Restricted
and Reportable Substances for Parts.
8 Coding System
This standard shall be referenced in other documents, drawings, etc., as follows:
GMW3112
9 Release and Revisions

This standard was originated in May 1998. It was first approved by the Interior Center in November 1998. It
was first published in November 1998.
GM Confidential
Issue Publication Date Description (Organization)
1 NOV 1998 Initial publication.
2 JUN 2001 Reformat Revision (GMNA)
3 MAR 2005 SAE/USCAR-24 replaces GMW3124, and Inflator Storage and Altitude
Resistance tests deleted.
• GMW14011 replaces GMUTS L-15-331 and GMW7293.
• Dual Depth Air Bag requirements added.
• Section 3.1 updated and subsections deleted.
• Sections 2.1, 2.2, 3, 3.2.1.1.1, 3.2.1.1.2.2, 3.2.1.1.2.3, 3.2.1.2.1, 3.2.1.2.2,
3.2.1.2.3, 3.2.1.2.4, 3.2.1.2.5, 3.2.1.2.6, 3.2.1.2.7, 3.2.1.3.1, 3.2.1.3.2,
3.2.1.4, 3.2.1.5, 3.2.1.7, 3.2.1.8, 3.2.1.9, 3.2.1.10, 3.2.1.12, 3.2.1.13,
3.2.1.14, 3.2.1.15, 4.1, 4.2, 4.2.1.1, 4.2.1.2, 4.2.2.1, and 4.2.2.2 updated.
• Noise, Service and Storage tests deleted from Sequential Tests.
• Salt Spray Test deleted.
Globally Approved. (GMNA)
• 3.2.1.1.2: Added KAB system deployment test procedures.
• 3.2.1.1.2.1 PAB System Static Deployment Test Procedure – Hot: clarify
Hot Test Procedure.
• 3.2.1.2 Sequential Tests: all DAB sequential tests & deployments to be run
4 JUN 2006 with DAB’s in Steering Wheels.
• 3.2.1.2.7 Squeak, Rattle & Other Audible Noise Avoidance: word
corrections.
• 3.2.1.3.1 Heat Aging – Low Humidity: Added system level trim conditioning
procedures table.
• 3.2.1.4: Clarify DOT/BAM PT1 requirements for different regions.
• 3.2.1.8 Ozone Test: delete the words “elastomeric or other”.
• 3.2.1.9 Electrical Stress Test: GMW3100 Inactive, replaced by GMW3097.
• Added 3.2.1.16 Out-Of-Position Body Block Test for Low Risk Deployment
PAB.
• Section 4: Clarify & correct the Module Level DV & PV matrices.
Corrected formatting errors and lists.
(Globally Approved by the Airbag/Steering Wheel GSSLT).
5 JUL 2006
6 DEC 2012 Five year refresh - document placed in current template. (Airbag/Steering
Wheel GSSLT)
Update system level testing to surface temperature deployment trigger
Commonize Thermal shock test profile with steering wheel
Replace BAM with CE conformity
Added KAB module integrity procedure
Added Emblem Deformation Resistance test
Added DV “lite” test matrix
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Appendix A
A1 Module Post Test Documentation

Vehicle Platform and Model Inflator Manufacturer ______________Type
Date Test Type:
Test No. Module Serial No.
Cushion Information Cover Information
Conditioning Cycle Deployment Temp
Cushion Integrity Description

Tears Yes/No
External (Qty ) Yes/No
Internal (Qty ) Yes/No
Tether(s) (Qty ) Yes/No
Vent Hole(s) (Qty ) Yes/No
Rupture Yes/No
Combing Yes/No
Stitching loss Yes/No
Holes in the cushion (define size and location) Yes/No
Tether separation Yes/No
Heat shield tearing/separation Yes/No
Melting of the cushion Yes/No
Cushion Fill Time
Describe any other visible cushion damage:
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GM Confidential
Cushion Attachment IntegrityDescription
Cushion separation from module Yes/No
Partial separation from module Yes/No
Rivets loose Yes/No
Rivet pull through/shear Yes/No
Cover retainer studs missing Yes/No
Z-bracket nuts missing Yes/No
Describe any other visible cushion attachment damage:
Inflator Description
No. of nozzles burst Front of
Rear of
Rupture of filter/Diffuser Yes/No
Inflator Attachment Integrity Description
Inflator retainer nut(s) missing Yes/No
Studs bent, loose or broken Yes/No
Straps pulled loose Yes/No
Inflator retainer distortion Yes/No
Describe any other visible inflator attachment damage:
GM Confidential
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Door, Trim Seat fabric Description
Door, Seat fabric Yes/No
Door fragmentation Yes/No
Pillar trim fragmentation Yes/No
Roof rail trim fragmentation Yes/No
Tear beyond or outside normal tear seam Yes/No
Retainer deformed Yes/No mm from straight
Rivet(s) separated Yes/No of
Describe any other visible damage:
Module Housing Description

Bellmouthing Forward edge mm
Rearward mm
Housing fragmentation Yes/No
Bracket(s) distortion Yes/No
Flange deformation Yes/No
Housing weld separation Yes/No
Post deployment photos taken Yes/No Qty =
Others (specify):
Signature: Date:
GM Confidential
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GMW 3112-2012

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ENGINEERING General Specification GMW3112

Verification of Requirements for Frontal Airbag Modules

3.2 Product Characteristics 4

4.1.1 Inspection and Preparation 31

December 2012 Originating Department: GME Specification Center Page 1 of 49

4.2 Validation Plan 31

6.2 Acronyms, Abbreviations, and Symbols 44 --```,``,`,,,`,``````,,-`-`,,`,,`,`,,`---

December 2012 Page 2 of 49

2007/23/EC IEC 60068-2-27 ISO 1431-1 USCAR-28

GMW3059 GMW3133 GMW14011 GMW14444

December 2012 Page 3 of 49

GMW3097GMW3286 GMW14096 GMW14595

Table 1: Test Condition Tolerances

Relative Humidity (RH) ± 5 % of RH

Acceleration ± 2 % except where minimums are stated

Frequency ± 4 % or ± 2 Hz, whichever is smaller

Voltage (in V) ±5%

Resistance (in ) ± 1.0 %

December 2012 Page 4 of 49

Purpose: To evaluate the Module performance structural integrity.

Module Cover and/or surrogate door (if required).

Lights (High intensity to enable viewing of all components).

2. Measure the resistance in shorted terminal-to-inflator-case. The resistance in shorted terminal-to-

December 2012 Page 5 of 49

h. Install thermocouples to measure the following Module Subcomponents

December 2012 Page 6 of 49

Figure 1: Heating Blanket

December 2012 Page 7 of 49

Figure 2: Fan Position

1 Fan positioned on centerline of airbag door opening.

Type K 24 gauge wire, 508 teflon wrap: K24-2-508 Temprel

Tig welded thermal couple junction for surface temperature recordings

One - On the PAB/KAB housing at centerline of occupant.

December 2012 Page 8 of 49

Figure 3: Thermocouple Position on I/P

1 Thermocouple location on windshield ≈ 30 mm above projected contact and ≈ 75 mm inboard. Not

December 2012 Page 9 of 49

One - Within chamber to record temperature.

3.2.1.1.2.1 PAB/KAB System Static Deployment Test – Hot.

December 2012 Page 10 of 49

Soak Temperature Deployment

Windshield Inner +75 +57

Deployment Door +102 +93

Deployment Door +75 +65

PAB/KAB Housing +75 +75

DAB module “A” surface +85 +75

December 2012 Page 11 of 49

replaced if/when they show signs of damage.

3.2.1.2.1 Dynamic Shock Test.

December 2012 Page 12 of 49

Table 3: DAB, PAB and KAB Dynamic Shock Schedule

Low G Test High G Test

Acceleration: 25G Acceleration: 45G

1980 total 18 total

Test Method: Test Method:

December 2012 Page 13 of 49

1. Drop temperature to -30 °C at the rate of 2 °C/minute.

Table 4: DAB, PAB and KAB Vibration Profile

Driver Airbag Passenger Airbag Knee Airbag

10 1.37E-01 10 1.37E-01 10 1.37E-01

95 5.41E-03 95 5.41E-03 95 5.41E-03

216 5.30E-03 216 5.30E-03 216 5.30E-03

465 3.89E-04 465 3.89E-04 465 3.89E-04