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This paper presents a new method for the 5mph vehicle's bumper section shape optimization. The Intermediate Response Surface Modeling (IRSM) technique is newly introduced to approximate the nonlinear force-deflection curves. This can avoid the excessive 3D nonlinear FEM analysis during the optimization process. Then, the accuracy of the IRSM models is examined by comparing their results with those of the 3D nonlinear FEM. Finally it is shown that the proposed approach is effective to design the 5mph vehicle bumper section.