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Zoox grounds Atlanta test fleet after workers report toxic gas exposure symptoms

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Zoox has grounded its autonomous vehicle test fleet in Atlanta after safety drivers were potentially exposed to carbon monoxide, carbon dioxide, or hydrogen sulfide gas inside its vehicles last month, TechCrunch has learned. The repeated incidents led one worker to file a complaint with the Occupational Safety and Health Administration, which opened an inquiry and told Zoox to investigate the exposures. 

As many as 40 workers were possibly exposed to the gases in the vehicles, according to a letter from OSHA to Zoox that TechCrunch viewed, though the Amazon-owned company says the number is lower.  

Zoox put at least one group of workers back on the road in a different car after one vomited and the rest reported exposure symptoms, a contractor told TechCrunch. That second car may have also contained potentially toxic gases, he said, because the workers experienced another bout of exposure symptoms later that day. 

“They made us go right back in the field after we said we were throwing up,” Jay Davis, one of the contractors who got sick in mid-August, told TechCrunch in an interview. “I emailed HR, told her what’s going on, and I told her I feel like it’s messed up that y’all made us go [back out].” 

Workers reported exposure symptoms and strange smells through much of last month until August 22, when someone called 911 for a sick worker. The facility in northwest Atlanta has operated at limited capacity since then, with the test vehicles quarantined while Zoox investigated the exposures, according to two employees. Zoox’s purpose-built robotaxis, which are all electric, are not affected.

TechCrunch spoke to Davis, who filed the OSHA complaint, along with one current and two former employees for this story. The other three workers were granted anonymity to discuss private company matters and because they fear retaliation. 

The illnesses come as Zoox branches into new cities and expands its existing operations in places like Las Vegas and San Francisco, in a bid to catch market leader Waymo. This rapid growth has put some safety monitors at risk. As TechCrunch previously reported, contractors have sustained injuries from sudden braking and swerving in the Zoox test vehicles. Waymo has also reported similar test driver injuries to OSHA.  

Exactly what gases the Zoox employees were exposed to remains unclear. Davis said he and two other workers who became sick were told at the emergency room that their symptoms were consistent with carbon monoxide exposure. The complaint filed with OSHA mentions possible carbon dioxide, or CO2, exposure. 

Zoox told OSHA in a September 10 letter, viewed by TechCrunch, that it examined its test vehicles for signs of CO2 and replaced their 12-volt batteries. Damaged batteries can produce hydrogen sulfide gas, which creates a “rotten egg” smell. Some of the employees who spoke to TechCrunch said they noticed a similar smell in the cars. 

Zoox identified 28 employees who rode in six test vehicles that had an “unexplained odor,” the company said in its letter to OSHA. Zoox told OSHA that 10 workers “voluntarily underwent medical evaluation” to “determine whether any exposure had occurred.” Zoox said in the letter that it received only “one medical report identifying CO2 exposure.”  

Zoox told TechCrunch it hasn’t identified the presence of carbon monoxide, which is odorless, in its vehicles. The company told TechCrunch it consulted an outside medical expert to help investigate the issues and that the only gas it detected in the impacted vehicles was CO2.  

In the letter to OSHA, the company said it will add CO2 monitors to the vehicles. OSHA has since closed its inquiry. 

“The safety and well-being of our Zoox test fleet operators is our primary concern in this situation,” the company told TechCrunch. “We are taking ongoing, appropriate, and cautious actions to investigate the reported events as necessary and support any needs from our operators. While we investigate these reports thoroughly, we have ceased operations of our test vehicles in this market.”  

Known risks

Cars produce carbon monoxide and carbon dioxide when they burn fuel. These gases can enter a vehicle if there is a leak in the exhaust system; they can also build up if a vehicle runs inside an enclosed space for an extended period. It’s a common enough problem that the National Highway Traffic Safety Administration investigated Ford for six years over reports of carbon monoxide buildup in its Explorer SUVs. 

In its letter to OSHA, Zoox said it tested the vehicles’ exhaust systems for leaks and performed a “smoke test” for cabin intrusions. It did not say whether it found any evidence of either. The company also removed all the 12-volt batteries, inspected them for damage, and replaced them. It did not tell OSHA whether it found evidence of damage to the batteries. 

The company keeps its test vehicles running through much of a given day, in part to maintain sensor calibration and reduce the onboard self-driving computer’s boot time. Zoox uses an exhaust capture system at its indoor depots — similar to what is used to capture truck fumes at fire houses — designed to mitigate the buildup of toxic gases.  

Zoox modifies the Highlander SUVs it uses for its test fleet. Most of that work focuses on adding sensors and an autonomy computer. But the company makes other changes, too, including adding an interior “snorkel” above the central infotainment screen that pushes air toward rear-seat passengers, the employees told TechCrunch.  

Zoox said it doesn’t modify the ventilation systems in these SUVs. But making any changes to a vehicle can increase the risk that gases will leak into the cabin. In the Ford investigation, the National Highway Traffic Safety Administration said in 2023 that the highest levels of carbon monoxide were found in police vehicles that had added sirens, lights, and other modifications, all of which can create sealing issues. 

Zoox is an outlier among major robotaxi developers because its test fleet vehicles have internal combustion engines. Waymo, Tesla, Avride, and Motional all use electric vehicles, which don’t produce exhaust gases. May Mobility’s test fleet includes some hybrid vans, and Nvidia uses a small number of gas and electric Mercedes-Benz sedans.   

“Everybody got quiet for some reason” 

Davis and the other employees said individual safety monitors started reporting possible exposure symptoms to Zoox at the beginning of August.  

The incidents Davis experienced on August 14 were more acute because four workers were riding in the SUVs together – a practice Zoox uses while training new employees. 

Davis told TechCrunch the first signs of trouble appeared early that morning. 

“Everything was fine. We was all laughing and talking, you know, just having a normal workday, and then everybody got quiet for some reason,” he said.  

Davis recalled that one of his colleagues asked if anyone else in the SUV was “feeling weird.” The crew was approaching their scheduled morning break at 10 a.m., so the workers stopped at a Chick-fil-A. As soon as they got out of the car, Davis said one of his co-workers started throwing up. He and the others felt lightheaded.  

They called the dispatcher at Zoox’s Atlanta depot, who arranged for the SUV to be towed back to base, he said. Meanwhile, Zoox arranged for an Uber to take the workers back to the depot.  

“As soon as we get back to base, we’re thinking, okay, since we’ve been sick and said we was lightheaded, you know, we’re gonna have like, you know, mild duties for the day. Just sit down, you know, get yourself back together,” Davis said. “No, they put us in another [test car] and they told us to go back to work.” 

After driving all afternoon, Davis said he and his colleagues went to a food court. He started vomiting after just a few bites of his meal.  

Davis contacted a representative from HireArt, the third-party contractor that technically employs Zoox’s test drivers in Atlanta. He said the representative gave him a workers’ compensation hotline number and told him to call Poison Control. Three of the workers went to the emergency room, where they were evaluated for carbon monoxide exposure.  

Davis said the emergency room doctor did not detect elevated carbon monoxide levels in his system. But he and others were told their symptoms were consistent with carbon monoxide poisoning.  

Workers continued getting sick in the days that followed, according to all four workers who spoke to TechCrunch. On August 22, one contractor got sick enough that someone at the depot called 911.  

It’s not immediately clear who called 911 or what happened to the sick worker. As for the four employees who reported symptoms on August 14, Zoox ordered them to take what it described as a random drug test in the days that followed.  

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Waymo is scaling fast. Here’s what the fleet data shows.

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Waymo’s commercial robotaxi ramp-up looks expansive, both in geographic reach and in ridership. And by almost every measure, it is — until you pay attention to where the bulk of those robotaxis are actually showing up.

The numbers over the past two years reflect the kind of commercial rollout you’d expect from a deep-pocketed company like Waymo, which spun out of Google and still counts Alphabet as its majority owner. In September 2024, Waymo was operating in just three cities — Phoenix, Los Angeles, and San Francisco. Today, it offers robotaxi service in 15 U.S. cities, with most of those commercial launches occurring in the past year. Ridership has skyrocketed, too with Waymo now averaging 500,000 paid robotaxi rides every week.

But a closer look at its fleet shows a company concentrating its efforts in just two states. About 80% of Waymo’s roughly 4,000 robotaxis are in California and Texas, and Texas is where the action is now: Waymo’s fleet there has grown by nearly half in the past three weeks, fueled by a new Chinese-built minivan the company is betting will help it scale, even as tariffs drive up its costs.

The other 800 or so vehicles are spread across cities in other states, including Arizona and Florida, another burgeoning hotspot. Most are the familiar white Jaguar I-Pace electric SUVs, but a growing share are that new minivan — a modified Zeekr RT that Waymo has branded “Ojai.”

Waymo’s focus on California is no surprise. It is headquartered in Silicon Valley, and much of its early testing and development work was conducted there. Plus, a segment of the population there is inclined to adopt tech at its earliest stages.

The recent growth in Texas is more interesting. Waymo has increased its Texas fleet by 49% in the past three weeks, according to state vehicle registrations and data from the Texas Autonomous Vehicle Fleet Tracker. As of September 24, Waymo had 1,102 autonomous vehicles registered in the state.

Waymo first launched in commercial service in Austin through a partnership with Uber in March 2025, letting riders hail its robotaxis through the uber app. Since then, the company has expanded its robotaxi services in Dallas, Houston, and San Antonio.

Waymo’s Texas fleet remained relatively static for most of the summer, inching up from about 600 vehicles in June to more than 700 by the end of August. Then came September, when the he fleet surged, driven by an influx of new Ojai minivans, which now make up about a third of Waymo’s Texas fleet.

Expect that share to grow.

The Ojai robotaxi, equipped with Waymo’s sixth-generation self-driving system, is supposed to help Waymo reach mass scale. Its interior is built to withstand heavy use, and it comes with an upgraded rider interface and Google’s Gemini AI, which acts as an in-car assistant for riders.

Strip away that technology, though, and the Ojai is a minivan made by Zeekr, a brand owned by China’s Geely Holding Group (which also owns Volvo). The Ojai is built on Zeekr’s SEA-M platform, a shared vehicle platform designed for uses like robotaxis and delivery vans. The base Zeekr vehicles are shipped to the U.S. without any Chinese connected-car technology on board. Once they arrive, the vehicles are sent to Waymo’s Arizona factory, where they are outfitted with Waymo’s self-driving system.

The Ojai is supposed to drive down costs and ultimately help Waymo reach profitability. For now, though, tariffs are cutting any savings. Under current U.S. trade policy, vehicles built in China face steep import tariffs, raising Waymo’s costs for every Ojai it brings into the country.

Waymo appears willing to absorb that cost. New York-based research firm MoffettNathanson, which tracks Ojai imports using detailed shipping records, said in its September report that Waymo is on track to bring 5,100 of the vehicles into the U.S. by the end of the year.

Where will all those Ojai vehicles go? Texas is certainly on the list. But Florida, where Waymo operates in three cities, and newer markets like Las Vegas will likely see an influx as well.

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Nexterity wants to automate the hard, dangerous part of pipefitting

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Lindsey Elliott is big into bolts. At last year’s Bolting Symposium — the 13th annual — she said the highlight was playing “Bolting Bingo” against the many self-proclaimed “torque dorks” who were in the room.

A former engineer and planner at ExxonMobil, Elliott has spent years thinking about how to improve the infrastructure that moves oil, gas, and petrochemicals. Bolts are what she landed on. Specifically, the bolts that connect sections of pipe (technically called “bolted flange joints”). These bolts require hard, physical work to loosen and tighten, and are the source of many pipefitters’ injuries. Like many trade industries, there’s also a labor shortage.

“Those people get really tired when they’re asked to work 12 hours a day for three months in a row,” she told TechCrunch. “I’ve talked to pipefitters across the U.S. across Canada, and just repeatedly have been told North American pipefitting productivity is notoriously low.”

The solution Elliott came up with at her startup Nexterity, which is one of the Startup Battlefield 200 selected to participate in TechCrunch Disrupt, is a remote-controlled robot that can handle this part of the job. It’s the kind of idea that could fundamentally change this particular blue collar job if widely adopted, making the workers safer and more productive.

Think: more dork, less torque.

The robot comes in two main pieces that fit around a pipe. Powered by batteries, the robot can slide across the pipe once it’s attached and quickly loosen and tighten four bolts at a time.

Elliott said Nexterity has developed a few different configurations of the robot to fit different standard pipe sizes, but they’re all small enough to fit in a Pelican case and be carried by a single worker. That makes them easy to deploy to new sites — flexibility that is crucial to Nexterity’s business model of treating the robot like rental construction equipment.

Elliott said she arrived at this particular design as a result of conversations she’s had over the last few years — not just at the Bolting Symposium, but also with members of the Pressure Vessels & Piping Division of the American Society of Mechanical Engineers.

“What I learned from the people, the torque dorks per se,” she said, “is that 80% of our pipes are between two to eight inches in diameter, or what they call NPS2 to NPS8. And so when you have that much repeatability, you have a fantastic candidate for automation.”

It’s a pretty straightforward idea, but one that Elliott believes has a lot of upside.

“I think it would shock a lot of people just how big this market is,” she said. “I mean, day to day, most of us don’t think about piping infrastructure, but even water, wastewater, water treatment, food and beverage, mining, nuclear, any kind of green and sustainable manufacturing facility — they all use the same kind of piping.”

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EPICS in IEEE Team Builds Portable Educational Platform

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In Guadalajara, Mexico, many high schools have motivated teachers and talented students with an interest in science, technology, engineering, and mathematics, but they lack access to advanced tools such as robotics laboratories. The resources shortfall limits the students’ opportunities for hands-on learning on cutting-edge applications.

A team from ITESO, Universidad Jesuita de Guadalajara, is working to change that. Through the EPICS in IEEE initiative, a multidisciplinary group of 15 engineering students, faculty advisors, and IEEE Guadalajara Section volunteers developed RoboMeshA. The portable, self-contained educational platform brings robotics and AI experiences into classrooms.

EPICS is administered by IEEE Educational Activities and funded by the IEEE Robotics and Automation Society.

A mobile laboratory

Rather than requiring a school to build a dedicated computer lab or install complex software, RoboMeshA operates as an all-in-one mobile learning network.

“RoboMeshA brings robotics and AI to students who don’t have access to specialized facilities or preinstalled software,” says team member Fernando Vidal Luna, an IEEE student member and a mechatronics engineering major at ITESO.

Students connect directly to the platform from a user-friendly web browser. They can interact with the robot manually or use its control modes to watch it move and detect and avoid obstacles.

“The project combines mechanical design, embedded systems, control engineering, computer vision, and AI into a single robotic system that functions as a mobile learning laboratory,” says faculty advisor Jorge A. Lizarraga.

The team says young students are interested in technology, programming, and robotics but don’t have an opportunity to work with systems that combine mechanics, electronics, software, and control.

“RoboMeshA allows students to see how all these disciplines work together in a tangible and understandable way,” says team member José S. González, who also is studying mechatronics engineering.

The team has built two units and is developing a modular coupling framework to expand the system’s capabilities for research and classroom demonstrations. The structured system design approach connects independent software components while minimizing internal dependencies, enabling four RobotMeshA robots to operate together.

Overcoming design challenges

The team faced significant hurdles while designing the project.

“One key challenge involved the robot’s structural design,” Luna says. “It wasn’t only about making a chassis where all the components fit and the design had sufficient stability, rigidity, and weight distribution. It was also about ensuring that the electronics were protected while still being accessible for maintenance, testing, and modifications.”

“It was also challenging to design a platform that could be used by students with different levels of experience,” González adds.

“When students realize the technology they develop can inspire others and improve lives, engineering becomes far more meaningful.” —Luis Fernando Luque-Vega

The team partnered with the CETI Colomos and Prepa ITESO high schools to validate the platform in classroom settings.

“We wanted the first interactions with the robot to be simple and intuitive,” González says, “such that students could simply power the robot, connect to its network, and begin interacting with it, rather than having to deal with software installation, extensive configuration, or troubleshooting.”

Engineering with social impact

Many of the students who participated were from ITESO’s applied professional projects program. The experience offered them practical training in project management, system integration, and user-centered design.

The team also presented a research paper and a project poster in May at the Engineering Congress of the Jesuit University System.

“Seeing a design move from a digital model to a physical system was invaluable,” González says. “Working with students from different backgrounds taught us to listen to end users and design for their actual needs.”

Project lead Luis Fernando Luque-Vega, an IEEE member, says he’d like the venture to serve as a blueprint for engineering education.

“I hope RoboMeshA is adopted by schools, universities, and IEEE student branches across Mexico and internationally as a model for integrating technical innovation with community engagement,” Luque-Vega says.

By pairing engineering talent with community service, initiatives such as EPICS in IEEE demonstrate how targeted support can turn academic concepts into real-world solutions.

“When students realize the technology they develop can inspire others and improve lives, engineering becomes far more meaningful,” Luque-Vega says.

For more information on service-learning opportunities, visit the EPICS website.

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