A former Tata Technologies engineer has revealed significant safety concerns regarding VinFast vehicles, coinciding with an ongoing National Highway Traffic Safety Administration (NHTSA) investigation into the Vietnamese automaker’s VF8 model via BBC.

Mechanical engineer Hazar Denli, who led chassis development teams at Tata Technologies for VinFast’s newer models, identified critical safety issues during prototype testing, including suspension component failures occurring at just 15,534 miles – far below the industry standard expectation of 93,205 miles. These concerns centered on fundamental chassis elements, including strut-to-knuckle connections and suspension components that could potentially lead to catastrophic failures during normal driving conditions.

The revelations come as NHTSA expands its investigation into the VinFast VF8, following 28 reported safety incidents. The investigation, which began examining 3,118 vehicles from the 2023-2024 model years, initially focused on Lane Keep Assist system failures but has since broadened its scope. Drivers report concerning issues with the system’s lane detection capabilities and steering inputs that prove difficult to override.

Of particular concern are Denli’s allegations regarding component failures during testing at the MIRA Technology Park facility. Multiple incidents of aluminum brackets, weighing approximately 4.4 pounds, reportedly detached completely from test vehicles. These components were allegedly carried over to VinFast’s newer VF6 and VF7 models from the current VF8 and VF9 platforms.

The timing of these revelations is particularly significant given VinFast’s recent public listing on the NASDAQ. The company pushed forward with production despite recommendations for comprehensive redesigns of problematic components, according to the whistleblower’s testimony.

Industry implications extend beyond VinFast, raising questions about quality control in rapidly expanding EV manufacturers and the role of engineering consultancies in vehicle development. The situation highlights the complex relationship between established automotive engineering firms and emerging EV manufacturers racing to market.

Tata Technologies and Jaguar Land Rover, both Tata Group companies, declined to comment on the allegations. VinFast maintains confidence in its safety standards while cooperating with the NHTSA investigation, stating: “We take all safety concerns seriously and will continue to monitor the situation closely.”

The case has drawn attention from automotive safety advocates and legislators, coinciding with proposed UK legislation to strengthen whistleblower protections in the automotive industry. The incident raises broader questions about quality control measures in the rapidly expanding electric vehicle sector, particularly among newer manufacturers partnering with established engineering consultancies.

For the expanding EV industry, this situation underscores the critical balance between rapid market entry and maintaining rigorous safety standards. As more new players enter the electric vehicle market, the industry may face increased scrutiny over development timelines and safety validation processes.

Photo courtesy of Vinfast.