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Laboratory testing and computer aided engineering (CAE) techniques have long been employed in the development and optimization of automotive bumper systems. However, as more aggressive automotive styling and performance trends and mass and cost reduction objectives continue to push the limits of known bumper system construction, early optimization techniques will need to improve proportionately. The limitations of today's test and analysis techniques for providing accurate predictions can lead to excessive factors of safety (waste) and/or expensive rework during latter stages of vehicle development. Much work has been done to improve the capability of computer simulations for predicting impact behavior (1). However, some of the development limitations can also be attributed to an inability to achieve repeatable results or to accurately simulate the low speed impact behavior of a vehicle with universal test vehicles (UTV).

The primary purpose of an automotive bumper is to protect the vehicle from damage, which may otherwise result from a low speed impact. Major insurance companies typically conduct low speed crash tests of new vehicles in order to establish appropriate insurance classifications based on the estimated costs to repair the resulting damage. One such test, which is carried out by the Allianz insurance organisation, has become the European standard by which automobile insurance rates are set. Although commonly known as the Allianz test, it may be more specifically referred to as the Danner test, after Max Danner, the originator of the test. This test is conducted at 15 km/h with a 0° oriented rigid barrier overlapping 40% of the vehicle for frontal collisions and a 1000 kg moveable barrier with a 40% overlap for impacts to the rear of the vehicle.