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Every year several thousands of unprotected road users are killed in car accidents. The European Commission therefore is working on new regulations to improve passive pedestrian protection on passenger cars significantly. Our study evaluates an example where the simulation is compared to results of tests which have been performed on a vehicle. For the simulation we used finite element impactor models which are validated not only to the certification tests, but also to the vehicle which has been used and to the test equipment where the tests have been performed. Based on these data possible solutions for future developments are discussed and rated in this paper.

The goal of virtual interior development is the virtual release of components avoiding the usual “try and error” method. This paper gives an example how this process was realized for an a-pillar in a vehicle. We started the process in the early development phase of the interior components, where we evaluated a concept on which the surface design of the component was based. By using validated material models for the FMH-simulation, the solution for the deformation concept complying with FMVSS 201u was found without the need of prototype components. Based on the results of virtual data from the simulation, the final solution was released. Testing on the hardware together with a comparison of the results to the calculations finally verified the solution. In this way, the concept of this example's a-pillar trim could be released.