Abstract
The present paper outlines the use of a systematic approach that combines structural computer-aided engineering (CAE) simulations and Design of Experiments (DOE) for the optimization of the structural performance of crushable thermoplastic energy absorbers to be used in door panels and upper interior trim. The use of DOE allows the evaluation of critical design and material parameters which affect the performance of the system. For interior components, these parameters include material properties such as modulus, yield strength and plastic strain limit; and geometric factors such as absorber shape, thickness distribution, rib depth and rib spacing.