Takata Quietly Changed Airbag Propellant in 2008 Amid Safety Fears
Takata altered its airbag inflator design in 2008 to address injury risks, but did not disclose the change to automakers or regulators at the time.
Takata made a secret change to its airbag inflator propellant in 2008, prompted by concerns over injury risks from its original formula. The company did not publicly disclose the switch at the time, even as it continued to assure automakers and regulators that its airbags were safe.
The decision to alter the propellant came after internal findings that humidity could destabilise the original chemical mixture inside the inflators. This instability increased the risk of the airbag deploying with excessive force, sending shrapnel into the vehicle cabin. The change in formula was made quietly, with no official announcement to carmakers or safety authorities. Around the same time, Honda initiated its first recall related to Takata airbags.
Why Takata changed the formula
Takata’s original inflator design used ammonium nitrate as the main propellant. Internal research and external incidents indicated that exposure to moisture could cause the propellant to degrade, making it prone to violent explosions during deployment. By 2008, Takata engineers had identified this as a critical safety issue and developed a revised formula less sensitive to humidity.
Despite the change, Takata did not inform its customers or regulators that a safety risk had been identified and addressed. The company continued to supply airbags with the new propellant while older designs remained in circulation. It was only years later, as injuries and fatalities mounted, that the full scope of the defect became public.
Impact on automakers and drivers
Most vehicles recalled for Takata airbag defects were manufactured before 2008, using the original propellant. Automakers including Honda, Toyota and others faced extensive recalls, legal claims and reputational damage. For drivers, the risks included injury or death from shrapnel when airbags deployed incorrectly. The US recall alone affected tens of millions of vehicles, with global numbers even higher.
Takata’s failure to disclose the propellant change raised questions about transparency and accountability in automotive safety. Regulators and carmakers were left unaware of the design alteration or the underlying risks until the defect became a public crisis.
What came next
By 2015, Takata had doubled its US recall to 34 million vehicles as the scale of the problem became clear. The company faced lawsuits, regulatory investigations and, ultimately, bankruptcy. The episode prompted renewed scrutiny of supplier practices and regulatory oversight across the industry.
