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I have a car seat that was loaned to a family member and returned with the internal styrofoam structure (under the fabric) broken on one side (see picture)

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Is the seat safe to use or do I need to get a new one?

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No. I would not risk it. Usually the manual will say not to use the unit if it's damaged, or even to use it if it's older than a few years. Parts may look just little bit damaged, but that little bit can cause a failure during an accident that will leave your little one hurt. Of course, like everything else, there's a tradeoff between cost (in this case free) and safety, but I personally would never use a damaged safety seat. Save money elsewhere, like by buying less plastic toys they get tired of after a day. :-)

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Or, better yet, have the family member who broke it contribute to the "buy a new carseat" fund. I would feel so guilty if I did that to someone! – Meg Coates Mar 23 '12 at 19:10
@MegCoates - +1, as would I, especially knowing how expensive they can be! – Shauna Mar 26 '12 at 16:21

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