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Recently, application of light-weight materials is increasing in the automobile industry to improve the fuel efficiency. The hybrid bumper beam consisted of the steel and plastic (GMT) is manufactured. If this process is introduced on automobile bumper beam, the mass of bumper beam can be dramatically reduced. In order to satisfy the regulation (FMVSS PART 581, IIHS), executed FEM (finite element method) analysis, low speed and high speed crash have been demonstrated. As a result, it was achieved mass reduction of 17%, while performance is maintained.

In recent years, pedestrian protection from passenger car impacts has become an important issue. In this study, a lower stiffener system has been implemented in order to reduce lower leg injuries. This system was developed using finite element analyses and impact testing. Injury criteria including bending angle, shear displacement, and deflection were studied in the analyses. These variables were optimized using a DOE (Design of Experiments) sensitivity analysis.