Abstract
To absorb the energy of an automotive crash, extruded aluminum sections can be used in the so-called crumple zone. The dynamic impact loads of these incidents are uncertain from their nature. Accordingly, the derived load collectives for the design of crashworthiness-relevant structures are imprecise and vague. First, an investigation is conducted on different triggering geometry for crash-absorbing longitudinal members. An adaptive surrogate optimization method is used to increase efficiency in design optimization. Uncertainty analysis using a fuzzy method is then employed to access the scattering of the structural responses at the optimal design. These methods are shown on a front crash system of extruded aluminum sections.