Mr. Caruso is a Mechanical and Electrical Engineer with more than 45 years of experience in the automotive industry, including nearly four decades specializing in the development and forensic evaluation of airbag systems, crash sensing algorithms, and occupant protection technologies. He has held senior technical leadership positions with General Motors, Delco Electronics, and Delphi, where he was instrumental in advancing many of the safety technologies still in use today. His career reflects a rare combination of hands-on engineering design, global product development, field investigations, and expert witness consulting, making him one of the foremost authorities in the field of airbag system design and crash sensing performance.

His early career at General Motors Institute and Delco Electronics placed him at the forefront of vehicle safety innovation. He served as Lead Systems Engineer for Automotive Safety Systems, where he helped establish the techniques and concepts for the first-generation Event Data Recorder (EDR) and Sensing and Diagnostic Module (SDM). He also authored the influential “Sensor Mounting Guidelines” specification, which became a reference standard for optimizing crash sensor mounting, implementation, and protection across OEM platforms worldwide. During this time, he investigated crash test results, resolved performance issues, and developed specifications that directly shaped industry safety practices.

From 1995 through the early 2000s, Mr. Caruso advanced to leading roles in Delphi’s Advanced Algorithm Development and Product Development teams. He designed and refined the algorithms that powered next-generation crash sensors, including the Electronic Frontal Sensor (EFS) and Side Impact Sensor (SIS), while also supporting early rollover detection technologies. His work resulted in six patents for crash-sensing algorithms, covering innovations in frontal, side, and rollover protection. He was a strong advocate for multipoint crash sensing systems, pushing the industry forward at a time when many suppliers still relied on outdated single-point designs.

In addition to his engineering design contributions, Mr. Caruso served as Technical Manager for Delphi Automotive Safety Systems, directing global teams across the U.S., Mexico, and Germany. In this capacity, he oversaw the development of the Passive Occupant Detection System (PODS-B) for advanced airbag systems, led technical design reviews for electronic control units, and provided regular training courses to engineers and OEM customer teams. His role required frequent international travel to diagnose system issues in field vehicles and during development testing, giving him unique firsthand insight into both the successes and limitations of safety system technologies in real-world use.

In 2007, he founded Automotive Safety Consulting, which later merged into ASC Forensics in 2023. His consulting practice is focused on the forensic evaluation of passenger vehicle crashes, including the analysis of airbag system design and performance, occupant classification systems, vehicle crashworthiness, and potential safety defects. He routinely conducts and interprets Crash Data Recorder (CDR/EDR) downloads, advises on the feasibility of safety system designs, and trains the ASC team on OEM design techniques and the methodology behind airbag design. His expertise has been sought in numerous product liability cases, where he has served as a consulting and testifying expert for both plaintiffs and defendants.

Throughout his career, Mr. Caruso has been recognized with numerous awards, including the Delco Electronics Boss Kettering Award for Engineering Excellence, the GM President’s Council Honors Award, and the Delphi Lead Award for Advanced Engineering. He has also authored SAE International Congress publications and presented technical papers on crash sensor performance and system development.

Mr. Caruso earned dual Bachelor of Science degrees in Mechanical Engineering and Electrical Engineering from the General Motors Institute, followed by a Master of Science in Engineering from Arizona State University. His career has been defined by a balance of research, innovation, and applied problem-solving — from patents and published papers to forensic investigations and courtroom testimony. Today, he brings this unmatched combination of technical knowledge and real-world insight to ASC Forensics, where he continues to provide authoritative analysis in complex automotive safety and crashworthiness cases.