Car airbags are both a very simple concept and a marvel of engineering, replacing the bone-shattering impact of unforgiving plastic and steel with a relatively soft landing in a funky-smelling air cushion. This deceptively simple concept requires that the gas generator activates only when there is a crash and finishes filling the airbag in the milliseconds before the squishy human’s cranium with its soft filling attempts to occupy the same space as said airbag. This makes mad Aussie bloke [Turnah81]’s attempt at DIY-ing a car airbag a most daring proposition.
Rather than messing about with an IMU and microprocessors, he went low-tech with an inertial fuel cut-off switch. These are mechanical switches that hold a steel ball in place with a magnet until a sufficiently large force — like a crash — dislodges the ball and triggers an event. Usually, a switch like this cuts off the fuel pump.
After a bit of fun with a crash-test rig and the airbag of a salvaged steering wheel, a DIY airbag was assembled using a compressed-gas cylinder instead of the fancy gas generator, along with an electrically triggered valve. Here, you can already see why modern airbags use a gas generator, as it is simply far more compact.
For the bag itself, a pillow case was adapted, with the subsequent crash test — as pictured above — going about as well as you can imagine. After this, he tried a few improvements, like using a bin liner and detonating some fuel, but it seems that the gas generator is very hard to beat for producing a large amount of gas in very little time.
Meanwhile, the inertial cut-off switch turned out to be more than sufficient for this purpose, and it was also used to trigger the original airbag. Of course, with how cheap those off-the-shelf airbag units are and are tested to be fit for purpose, you’d never DIY them for actual use in a car unless you were stark raving mad.
Airbags have a checkered history. There are some places you shouldn’t try to save costs.
