It's hard to say if Toyota's engineers skimped over a key piece of the development process with this particular example and I'm certain there's no way an engineering team can be expected to anticipate every possible failure given the practicalities and constraints of development cycles. That said, this example points up the very key requirement to do some level of design for misuse as part of the iterative process. It's one of those areas like design for assembly and disassembly that likely gets short shrift in a lot of companies and across myriad industries--not just automotive.
Altair has released an update of its HyperWorks computer-aided engineering simulation suite that includes new features focusing on four key areas of product design: performance optimization, lightweight design, lead-time reduction, and new technologies.
At IMTS last week, Stratasys introduced two new multi-materials PolyJet 3D printers, plus a new UV-resistant material for its FDM production 3D printers. They can be used in making jigs and fixtures, as well as prototypes and small runs of production parts.
In a line of ultra-futuristic projects, DARPA is developing a brain microchip that will help heal the bodies and minds of soldiers. A final product is far off, but preliminary chips are already being tested.
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