Bonnet weight reduction and VRU protection: Design proposals implementing non-conventional materials

The use of non-conventional and innovative materials is increasingly important in automotive design. They allow reductions in the weights of structures with consequent reductions in fuel consumption and carbon dioxide emissions. At the same time, they ensure excellent safety levels. Once excellent results in terms of active and passive safety have been obtained, the attention of car manufacturers, and of the public opinion, is focused on the safety of vulnerable road users (VRU), pedestrians and cyclists. Some examples concerning the redesign of a bonnet with the double targets of weight reduction and pedestrian safety are illustrated. Hybrid metal/plastic and more conventional metal sheet solutions are compared. The static performance (stiffness and denting resistance), as well as the impact against a pedestrian head, are evaluated by means of FEM models along with actual regulations.