A driver airbag module has been developed with single stage inflator in an attempt to determine the 05th% ATD measured dummy injury response (“MDIR”) in out-of-position scenarios (two NHTSA positions). Through computer simulations, dynamic MDIRs for in-position 05th%ile and 50th%ile dummies were evaluated as well.It typically takes many design iterations to finalize a driver side module configuration to meet FMVSS208 regulatory conditions. Some typical parameters are tear seam cover design, cushion folding pattern and inflator output. In this paper, a Taguchi design of experiments was used to evaluate the influence of module design parameters. A MDIR comparison between a proposed new driver airbag module with a single stage inflator and a baseline module with a dual stage inflator was made not only for out-of-position tests, but also in-position crash simulations.Currently in the US market, a majority of driver airbag modules use dual stage inflators to meet the injury assessment reference value (“IARV”) criteria set by federal regulation. This driver airbag module with single stage inflator will give car manufacturers an option to eliminate the seat track position sensor and to reduce the number of wire harnesses which are required to connect the dual stage inflator. An additional benefit would be a simplified airbag control unit involving both algorithm and hardware. This simplification should be accomplished while providing comparable MDIR for both in-position and out-of-position scenarios over a baseline module with a dual stage inflator.