India’s automotive sector stands at a pivotal moment with the proposed Bharat NCAP 2.0 draft, released by the Ministry of Road Transport and Highways (MoRTH) in late 2025.
This update promises to elevate crash testing standards, addressing gaps in occupant protection while opening new avenues for manufacturers.
For B2B stakeholders, understanding these shifts is crucial amid rising safety demands and export ambitions.
Original Bharat NCAP Framework
Launched in 2023 under AIS-197, Bharat NCAP initially focused on three core assessment areas for M1 category vehicles up to 3.5 tonnes GVW: Adult Occupant Protection (AOP), Child Occupant Protection (COP), and Safety Assist Technologies (SAT).
Key tests included a 64 km/h offset deformable barrier frontal impact, 50 km/h side mobile deformable barrier impact, and 29 km/h pole side impact, using Hybrid III and Q-series dummies.
Scoring allocated 32 points to AOP (16 each for frontal and side), 49 to COP (dynamic tests plus installation checks), with SAT as a qualifier via features like ESC, pedestrian protection, and seatbelt reminders.
Star ratings ranged from 1 to 5, with thresholds like 27/32 AOP points for 5 stars. By mid-2025, 21 vehicles were tested, with 18 securing 5 stars, including Tata Nexon EV (29.86/32 AOP) and Mahindra models.
Key Changes in Bharat NCAP 2.0 Draft
The 2025 draft expands to a five-pillar structure: Crash Protection (55%), Vulnerable Road User (VRU) Protection (20%), Safe Driving (10%), Accident Avoidance (10%), and Post-Crash Safety (5%). This holistic approach integrates pedestrian and cyclist safeguards, previously underrepresented.
Crash tests now mandate five scenarios: 64 km/h offset frontal, 50 km/h full-width frontal, 50 km/h side, 32 km/h oblique pole side, and 50 km/h rear impact doubling from the original three.
VRU tests introduce legform, adult/child headform impacts on bumpers and bonnets. Stricter rules bar 5-star ratings if any vertical scores zero or dummies show “red zone” injuries pre-modifiers; 3+ stars require 55% AOP in Crash Protection.
EV-specific checks for battery protection and thermal management gain emphasis, alongside mandatory ESC and side head protection across variants no fitment rate leniency.
Post-crash evaluates fire risks, e-call systems, and rescue ease. Public comments closed December 20, 2025, signaling imminent rollout.
| Assessment Pillar | Weightage | Key Additions in 2.0Â |
| Crash Protection | 55% | Full-width frontal, rear impact; 55% AOP min for 3+ stars |
| VRU Protection | 20% | Pedestrian leg/headform tests |
| Safe Driving | 10% | Enhanced seatbelt reminders, child checks |
| Accident Avoidance | 10% | AEB voluntary but scored; ESC mandatory |
| Post-Crash Safety | 5% | Fire/electrical hazards, e-call |
Testing Data and Performance Trends (2025 Onward)
In the first half of 2025, Bharat NCAP tested nine models, with most earning 5 stars: Tata Harrier EV, Mahindra XEV 9e, Kia Syros, Skoda Kylaq, and Maruti Dzire (higher trims).
Maruti Baleno and Basalt scored 4 stars, highlighting child seat and AOP variances. By June 2025, across 24 tests, 22 achieved 5 stars, with EVs like Nexon EV (April 2025 retest) perfect in AOP.
These results underscore a shift: 6 airbags now baseline for top ratings, boosting market share for compliant OEMs. Costs dropped to Rs 60 lakh per test versus Rs 2.5 crore globally, aiding local labs like ARAI and ICAT.
Challenges for Automakers
Smaller OEMs face steep cost pressures from redesigned structures, added tests, and EV battery reinforcements potentially hiking entry-level prices.
Infrastructure lags: India needs more certified labs amid rising test volumes. Compliance deadlines, like mandatory ratings from August 2025, risk launch delays for non-compliant models.
Stricter 2.0 criteria could downgrade existing 5-star cars; e.g., zero VRU tolerance penalizes legacy designs.
Export-oriented firms must align with Global NCAP, but domestic focus on affordability clashes with premium safety. Upskilling engineers in ADAS and VRU design adds timelines.
Opportunities and Strategic Imperatives
Bharat NCAP 2.0 positions compliant vehicles for exports, matching Euro NCAP rigor and appealing to safety-conscious global buyers. Market leaders like Tata (8 tests, all 5-star) and Mahindra (5 tests) gain credibility, capturing share as consumers prioritize ratings, 6-airbag models now outperform.
OEMs can innovate in ADAS (AEB, LKA upcoming), post-crash tech, and VRU-friendly hoods, differentiating in EVs where battery safety scores high. Local testing cuts costs 75%, spurring ARAI/ICAT expansions. B2B partnerships for shared R&D emerge, especially India-Japan ties in power electronics.Â
Mandatory from August 2025, it enforces upgrades, reducing India’s 150,000+ annual road deaths (20% pedestrians). Forward-thinking automakers view it as a competitiveness booster.
Future Outlook for India’s Auto Ecosystem
As Bharat NCAP evolves, expect 2026 integrations of ADAS and 6G-enabled safety, aligning with EV push.
EV-specific challenges in Bharat NCAP battery tests primarily revolve around crash-induced deformation, thermal runaway risks, and post-crash electrical isolation.Â
These issues demand advanced battery packaging and monitoring, complicating designs for Indian automakers.
Core Protocol Requirements
Bharat NCAP mandates continuous voltage monitoring of the high-voltage battery during frontal, side, and pole impacts.
Labs must drain the battery to simulate real-world states within 15 minutes pre-test, or use an auxiliary pack connected directly to preserve original wiring ensuring no alterations affect outcomes.
- Post-crash, automatic isolation is scrutinized, with warnings for fire hazards; failure risks score penalties in the new 5% Post-Crash pillar.
- 2025 updates intensify scrutiny on floorpan intrusion, battery enclosure integrity, and thermal management to prevent electrolyte leaks or shorts.
- EVs like Tata Nexon EV aced these in retests, but protocols align with AIS-156 abuse tests (vibration, overcharge, fire resistance).?
Key Engineering Hurdles
Battery packs must endure 64 km/h offset frontal loads without intrusion breaching cells, a tough ask for underbody-mounted designs in affordable EVs.
India’s hot climate exacerbates thermal runaway post-impact heat spikes demand robust cooling, yet adds weight and cost (10-15% BOM hike).
Infrastructure gaps persist: Labs like ARAI/ICAT upgrade for containment and real-time monitoring, but scaling for high-volume testing lags. Smaller OEMs struggle with certification under AIS-038 Rev 3 (Phase 2: thermal propagation, earth leakage), mandatory since 2023 but NCAP-enforced now.
| Challenge | Impact on OEMs |
| Intrusion Resistance | Redesign chassis for underbody protection; +5-10% structural cost |
| Thermal/Fire Safety | Integrate BMS with 4+ sensors, active cooling; fire risk myths amplify scrutiny |
| Post-Crash Isolation | HV cutoff in ms; e-call integration for occupant count/fire alerts |
| Testing Logistics | 15-min drain, aux battery setup; lab capacity bottlenecks |
Pushing Innovations in Structural Batteries And AI-BMS
These protocols push innovation in structural batteries and AI-BMS, benefiting leaders like Tata, Mahindra but pressuring budget players.
Compliance boosts ratings critical as 2025 tests showed EVs matching ICE in AOP but excelling in isolation.
Forward integration with Bharat NCAP 2.0 VRU/post-crash pillars offers differentiation amid EV push.
