Development of a One-Piece, Injection Molded, Thermoplastic Rear Bumper System with Pole Impact Protection

The first single-piece, rear bumper system injection molded from an engineering thermoplastic provides 8 km/h pole impact as well as required Federal Motor Vehicle Safety Standard (FMVSS) protection requirements for a small passenger vehicle. The system's efficient design features integral fascia support, eliminating bracketry and providing assembly savings at the plant. The bumper offers a 1.5 kg mass savings compared to conventional aluminum and polypropylene foam bumper systems. Additionally, its low intrusion design means neither the rear end panel nor the deck lid was damaged at the 8 km/h impacts tested.

This paper will describe the bumper's design, development, and validation process, plus describe the results achieved to date.