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This paper presents a methodology for digital design of a bumper system with energy absorber that caters to low velocity impact with a rigid barrier with maximum energy absorption and minimum barrier intrusion with constraint on transmitted rail loading. This gives rise to a conflicting situation and a genetic algorithm based multi-objective optimization software GDOT, developed in-house, is used to come-up with an optimal pareto-front. The technique employed here treats multiple objective functions separately without combining them in any form. A decision-making criterion is subsequently invoked to select the “best” subset of solutions from the obtained non-dominated Pareto optimal solutions.