Design defects are intended elements of the design itself that are defective. For example, if an automobile does not promote safety of its occupants due to the design of its frame, design defects are evident. A design defect is also present when the risks a design poses are greater than its benefits.

Defective Brakes

Design flaws in a braking system may not always be noticeable until they fail, causing an accident and injuries to vehicle occupants.

Rollover Risk / Center of Gravity Flaws

Sports Utility Vehicles (SUV), pick-up trucks and mini-vans are the most likely vehicles to be designed with a high center of gravity. This places these vehicles at a much higher risk of a rollover.

Seatbelt Design

Design flaws that produce slack in a belt or cause seat belt latches to fail during an accident expose occupants to serious injuries. Seatbelt webbing that fractures in the event of a crash can cause passengers to be thrown about during impact and collide with the vehicle's interior.

Fuel Tank Design

Fuel tanks that are placed incorrectly or are badly designed are likely to present a risk of explosion during an accident. Also, faulty fuel tank design can cause gas leaks, resulting in explosions and fire hazards.

Seat Design

Seats that collapse during an accident can cause major injuries to occupants. Design defects can affect the stability of the anchor, seatback and seat headrest, leading to seats that are ripped from the rails in the event of a crash, causing serious injuries.

Defective Tires

Tires that are incorrectly designed can lead to loss of road grip during an accident. Poor design can also cause tires to blow out, causing the vehicle to run out of control, and contributing to a rollover.

Defective Steering Design

Any defect in the steering mechanism of the automobile or parts of its design system can cause a motorist to lose control of a vehicle leading to an accident.

Since 1996 when the National Highway Traffic Safety Administration [NHTSA] was authorized to set standards for automobile safety and require automobile companies to recall defective vehicles, millions of automobiles including passenger cars, commercial trucks and motorcycles have been withdrawn from the market.

Often, auto manufacturers cut back on correct design processes in an effort to cut costs and speed up delivery schedules. By the time a defective vehicle is recalled, it could have contributed to several accidents and injuries.