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This article discusses steps to predictively estimate the responses of Anthropomorphic Test Device (ATD) in a side impact event, based on a Side Airbag (SAB) Force-Deformation (F-D) characteristics derived from the linear impactor test. A critical load management challenge that has been used to assess this predictive response process is the oblique pole impact test - part of the FMVSS 214 protocol. In this scenario, the ATD is assumed to have a free travel until it is stopped by the crushed and stacked up door against the rigid pole. Three critical energy management paths involved to manage the kinetic energy of the ATD at impact are assumed at the onset, namely, the door trim crush, ATD torso loading and most important efficient energy management of the SAB at a controlled force level. The SAB energy management is assumed critical and tied with the final response of the test ATD.

NHTSA issued the FMVSS 226 ruling in 2011. It established test procedures to evaluate countermeasures that can minimize the likelihood of a complete or partial ejection of vehicle occupants through the side windows during rollover or side impact events. One of the countermeasures that may be used for compliance of this safety ruling is the Side Airbag Inflatable Curtain (SABIC). This paper discusses how three key phases of the optimization strategy in the Design for Six Sigma (DFSS), namely, Identify; Optimize and Verify (I_OV), were implemented in CAE to develop an optimized concept SABIC with respect to the FMVSS 226 test requirements. The simulated SABIC is intended for a generic SUV and potentially also for a generic Truck type vehicle. The improved performance included: minimization of the test results variability and the optimization of the ejection mitigation performance of the SABIC.