In a concerning development, the National Highway Traffic Safety Administration (NHTSA) announced on Monday that it is closely monitoring data from a group of mostly unrecalled Takata airbag inflators after an explosion occurred in a BMW vehicle, causing severe injuries to the driver in Chicago. The investigation into this batch of approximately 30 million inflators began in 2021, as the NHTSA sought to determine if they exhibited the same dangerous traits that forced Takata to recall 67 million devices since 2001.

The incident in question involved a 2014 BMW X3, where the inflator exploded on October 23, shooting a large gold-colored metal disc that had to be surgically removed from the driver's lung. This incident prompted BMW to issue a recall of 486 SUVs equipped with Takata airbags. The NHTSA complaint revealed that the ruptured inflator was attributed to a welding defect in manufacturing, marking a departure from previous recalls related to Takata airbag gas generators, which were primarily caused by propellant aging.

This is not the first time inflators with a desiccant, a moisture-absorbing chemical, have been subject to recalls. General Motors recalled nearly 900 vehicles in July due to a manufacturing defect in Takata inflators with desiccants. Likewise, in 2020, Volkswagen recalled around 370,000 Passat and Beetle cars from 2012 through at least 2016 because of a propellant issue. The NHTSA clarified that the GM and BMW recalls originated from the same group of inflators and were a result of manufacturing problems, rather than propellant degradation. The Volkswagen inflators, however, had a different propellant mixture than those in the GM and BMW vehicles.

The NHTSA had previously decided not to recall Takata inflators with desiccants in May 2020 but said it would continue to monitor them. However, documents from the investigation reveal that desiccants become saturated over time, raising concerns that the same deterioration process observed in inflators without desiccants may also occur in inflators with them. Michael Brooks, executive director of the Center for Auto Safety, expressed skepticism about the automakers' response, suggesting that they may be downplaying the issue to limit recalls and cut costs.

Following the recall, BMW stated that affected owners would have their airbags replaced free of charge, with notifications set to be sent out starting January 16. The ongoing investigation encompasses over 30 million inflators in more than 200 models from various car and truck manufacturers, including Honda, Stellantis, General Motors, Ford, and Nissan, among others. The NHTSA reassured the public that they would continue to closely monitor airbag inflator issues and take necessary action if any safety defects are identified.

Takata's faulty airbags have been responsible for numerous deaths and injuries worldwide. At least 26 people have been killed in the U.S. by Takata inflators since May 2009, with a total of 30 deaths reported globally, including in Malaysia and Australia. Additionally, approximately 400 people have been injured as a result of these defective airbags. The widespread recalls and legal repercussions led to Takata filing for bankruptcy.

The recent incident with the BMW airbag recalls highlights the potential dangers associated with inflators that use a desiccant to keep the ammonium nitrate propellant dry and stable. As investigations continue, the automotive industry will be closely monitoring the situation to ensure the safety of their vehicles and drivers.