That's a pretty frightening story. Who could possibly have predicted somthing like that happening?

Last week I replaced a rear door window on my daughter's car, shot out by, I figure, kids on a teacher's meeting day. They aimed, I think, to hit our 245 side window too, but that round went through the screen and both panes of our thermal glazing on the house. Made neat little 1/4" holes in the house window, but the tempered glass in the car just instantly turned into a million tiny cubes and tiny sharp slivers.

The only thing I can imagine is an alignment problem with the regulator and/or the door frame, causing a pressure bias on the glass when raised, right on the verge of breaking. This happens sometimes with fixed glass, when the weather changes, following an accident that appeared not to damage things, but actually placed stress on the glass mounting. I have no idea if you have any history to suspect something like that.

Also, in 240s with electric windows, I find the M6 hardware attaching the regulators to the door panels are frequently loose. I wonder if that causes them to drop out of alignment too.

You have my sympathy for your personal injury and the shock of the event.
--
Art Benstein near Baltimore