• Comprehensive safety concept offers enhanced protection for drivers, surroundings, and rescue teams
• Real-world crash test confirms structural stability and integrity of the battery
• Accident research integrated into development from the very start

Leinfelden-Echterdingen/Neumünster – The battery-electric Mercedes-Benz eActros 600 for long-distance transport combines efficiency and sustainability with the highest standards of active and passive safety. Early on in the development phase, Mercedes-Benz Trucks' internal accident research team evaluated existing real-world accident data and applied it specifically to the vehicle's design elements. The objective was to consistently tailor protective measures to typical heavy-duty accident scenarios.

As part of one of several real-world crash tests in Neumünster, Schleswig-Holstein, the eActros 600 was subjected to a side impact of the kind that can occur in serious road accidents. The test result: Despite the considerable force exerted, the entire high-voltage battery system and all electrical components remained intact. 

“From the outset, our aim was to make no compromises when it came to vehicle safety,” says Felix Pietler, passive safety developer at Mercedes-Benz Trucks. “With electric drives in particular, it is not only important to ensure passenger protection – measures to protect the immediate surroundings are also crucial.” 

Comprehensive crash concept ensures survival space under extreme conditions 

The reinforced cab and defined energy absorption zones in the front end of the vehicle dissipate impact forces in frontal collision scenarios in a targeted manner via crash-optimized structures. With regard to side impact scenarios, the latest test confirmed that the high-voltage battery modules remained intact and the housing showed no critical deformations thanks to a frame architecture specially developed for heavy-duty collisions. In addition, airbag systems and seatbelt tensioners are available to increase occupant protection in all vehicle variants. Frank Müller, Head of Accident Research & Passive Safety at Mercedes-Benz Trucks, adds: “The test showed that the mechanical stress was high – but our concept works reliably.” 

A glimpse behind the scenes of a special test 

Prior to the test, simulation-based analyses were carried out and sensors were installed and precisely calibrated; each component was precisely tailored to the test scenario. 

“For me personally, the last two to three minutes before the crash are particularly fascinating,” says Christoph Berger from the Passive Safety team, describing the moment just before the test sequence is triggered. “Everything becomes quieter than before, and there is a concentrated tension in the air.” Upon impact, more than a ton of mass collides with the side of the truck at a speed of over 50 km/h. 

High-voltage system designed for safety 

The high-voltage (HV) system, including batteries, meets strict internal requirements in terms of insulation technology, mechanical protection, and fire protection components to reduce potential risks after severe damage. Production vehicles thus meet all current legal standards as well as brand-specific test criteria that are significantly above regulatory requirements. 

After each physical test, a release check is first carried out by specialized emergency services; only then does the detailed dismantling of central components begin for damage analysis against simulation data. 
Müller summarizes: “The results clearly confirm our expectations; there would have been no danger here in practical use.” 

Why testing continues even after series production has started 

Mercedes-Benz Trucks conducts regular physical tests, even when a model is already in series production, in order to derive continuous improvements. New findings from field data are continuously fed back into the product range. This ensures that technological developments can be implemented promptly, legal changes are complied with, and new customer requirements are taken into account. 

With this approach, Mercedes-Benz Trucks is consistently pursuing its Vision Zero goals for maximum road safety for both conventional and battery-electric heavy-duty vehicles in Europe. 

Supplementary active assistance systems^[1]:

The Mercedes-Benz eActros 600 not only marks a milestone in CO2-free long-distance transport, but also impresses with its modern safety and assistance systems. These include Active Brake Assist 6 with 270-degree environment monitoring, which can detect potentially dangerous situations and bring the vehicle to a standstill independently if necessary, and Active Sideguard Assist 2, which can effectively support the driver, especially when turning and changing lanes. Front Guard Assist monitors the area directly in front of the truck, providing additional protection for pedestrians and cyclists. Active Drive Assist 3 enables semi-automated driving on the highway, relieving the driver on long journeys, while Attention Assist 2 can warn of inattention and fatigue. 

The Mercedes-Benz eActros 600 is very quiet on the road, benefiting both drivers and the environment. To ensure that vulnerable road users such as pedestrians and cyclists can still hear the electric truck in their vicinity, it is equipped with an external Acoustic Vehicle Alerting System (AVAS) in accordance with legal requirements. Depending on the driving conditions, sounds are played for forward or reverse driving. In addition, the sound varies depending on the driving speed and accelerator pedal position, enabling good acoustic perception in city traffic. The futuristic sound spectrum of the AVAS installed in the eActros 600 is designed to reflect the appearance of a heavy vehicle and contribute to better recognizability in city traffic. 

About the eActros 600

Mercedes-Benz Trucks celebrated the series launch of the eActros 600 at the end of November last year at the Mercedes-Benz plant in Wörth. Deliveries to customers began in December 2024. The electric flagship from Mercedes-Benz Trucks has already proven its capabilities several times under real-life conditions: In customer use and as part of the “eActros 600 European Testing Tour 2024”, a 15,000-kilometer all-electric development trip through a total of 22 countries and the “European Testing Tour Winter 2025” on around 6,500 kilometers through Northern Europe, each with a gross combination mass of 40 tons. In addition, the e-truck was voted “International Truck of the Year 2025”. The award is the most important prize in the industry and is presented annually by the International Truck of the Year (IToY) organization, consisting of 24 commercial vehicle journalists from Europe.

The high battery capacity of over 600 kilowatt hours - hence the model designation 600 – and a new, particularly efficient electric drive axle developed in-house enable the eActros 600 to achieve a range of 500 kilometers^[2] without intermediate charging. This range is accomplished under very realistic and practical conditions with a gross combination mass of 40 tons, which can also be significantly exceeded depending on the driving style and the route. The eActros 600 will even be able to cover well over 1,000 kilometers per day. Intermediate charging during statutory driver breaks makes this possible, provided that charging options are available.

The eActros 600 has three battery packs, each with 207 kWh^[3]. These offer an installed total capacity of 621 kWh. The batteries are based on lithium iron phosphate cell technology (LFP) and are characterized by a long service life. The development engineers at Mercedes-Benz Trucks designed the eActros 600 to meet the same requirements for the durability of vehicles and components as a comparable conventional heavy-duty long-haul Actros. This means up to 1.2 million kilometers in ten years of operation. After this period of use, the battery state of health should still be above 80 percent. In contrast to other battery cell technologies, more than 95 percent of the installed capacity can also be used with LFP technology. This facilitates a higher range with the same installed battery capacity. The vehicle is technically designed for a gross combination mass of up to 44 tons. With a standard semitrailer, the eActros 600 has a payload of around 22 tons in the EU. There might be cases in which national law allows higher payloads.

In order to meet even more customer requirements, Mercedes-Benz Trucks recently expanded its battery-electric truck portfolio with additional variants based on the Mercedes-Benz eActros 600. Depending on their requirements in terms of range, payload, and comfort, customers will be able to choose between two cab variants, two or three battery packs, numerous wheelbases, and new axle configurations. The second model generation of the eActros thus offers over 40 variants of the base vehicle. The new vehicle versions feature the key characteristics of the eActros 600, such as LFP battery technology and the specially developed eAxle.

_{[1] Assistance systems can only support drivers. The responsibility for driving the vehicle safely always remains entirely with the driver.
[2] The range was determined internally under specific test conditions, after preconditioning with a 4x2 tractor unit with a 40 tons total towing weight at 20°C outside temperature in long-haul operation and may deviate from the values determined in accordance with Regulation (EU) 2017/2400.
[3] Nominal capacity of a new battery, based on internally defined boundary conditions. This may vary depending on the application and ambient conditions.}