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Improving passenger car damageability has been an important topic for The Insurance Institute for Highway Safety (IIHS) and the Research Council for Automotive Repairs (RCAR) council. Incorporation of new IIHS/RCAR barrier (Rigid bumper shaped barrier fitted with an energy absorbing material and cover) in ‘Bumper Structural Test protocols’ closely replicates the damage patterns observed in real world low-speed crashes. Inclusion of new IIHS/RCAR barrier impact (10kmph speed) test, along with IIHS and RCAR bumper test protocols, redefines the development of countermeasures for low speed damageability. In this paper an innovative cost effective, and lightweight, hybrid bumper beam solution is proposed with thermoplastics and steel, to meet IIHS and RCAR impact requirements including new IIHS/RCAR barrier impact test protocols.

As the pedestrian impact regulations are continuing to evolve, there is a growing emphasis on each and every component of a vehicle front to be pedestrian friendly. Traditionally pedestrian safety during an automotive impact is ensured through bumper, grill, fender and hood. However, the headlamp design was not under the same level of consideration as compared to other frontal components. To make pedestrian safety complete, the headlamp also needs to adhere to the pedestrian safety regulations. A novel energy absorber ring (EAR) concept was developed to make the headlamps pedestrian friendly. The proposed EAR concept was found to improve the pedestrian safety and low speed vehicle damageability performance. It was also observed that the proposed concept reduces the replacement and insurance cost.