Vehicle front ends have evolved over the last 10 years into lightweight, low cost, high performance complete modules.
Now, the development of such modules implies considering not only customers styling trends but also conflicting mechanical constraints at different speeds.
In one hand, a front end module must control fast loading under an insurance crash test in order not to deform the car structure, to minimize components damage and therefore reduce collision repair costs, whereas in the other hand, the front end module must provide enhanced occupant and pedestrian safety by absorbing energy in the most efficient way (vehicle to pole tests, EEVC WG17 proposed subsystem tests). Still, the bumper must meet customers specifications under low speed impacts.
Faurecia, based on its wide experience and know-how in front end module design, has adapted its development tools in order to take into account occupant and pedestrian protection in the same time as low speed and insurance tests specifications.
The aim of this paper is to illustrate the development of a front end module structure regarding pedestrian protection and to put forward the possible conflicts between pedestrian protection and structure performance in crash when the vehicle environment (structure / style) is more or less imposed.