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The effect of polyurethane structural foam on strength, stiffness, and energy absorption of foam filled structural components is investigated to formulate design directions that may be used in weight reduction and engineering functions of vehicle systems. An experimental/testing approach is first utilized using Taguchi’s DOE to identify design variables [foam density, gage, and material type], that are needed to determine the weight/performance ratio of structural hat-section components. An analytical CAE approach is then used to analyze the hat-section components using non-linear, large deformation finite element analysis. An accepted level of confidence in the CAE analytical tools is then established based on comparison of results between the two approaches.