Target Setting

We establish clear performance goals driven by market demands and regulations:

• Customer-focused safety levels aligned with New Car Assessment Programs (Euro NCAP, ASEAN NCAP, C-NCAP)
• Regulatory requirements (ECE UN Regulations, GSO, FMVSS, CCC)
• Vehicle segment and usage-case considerations 

System Definition

Based on performance targets, we specify the optimal suite of safety systems:
• Airbag variants and features
   o Front, side, curtain, knee, rear center airbags
   o Multi-stage inflators and adaptive deployment strategies

• Seat belt technologies
   o Pretensioners, load limiters, belt force adaptivity

• Pedestrian and cyclist protection
   o Active hood lift hinges
   o Energy-absorbing bumper and cowl structures
   o Sensor-driven pre-crash countermeasures 

Test Matrix Definition

We design a comprehensive test plan covering prototypes and configurations:
• Prototype count and builds for subsystem, full-vehicle, and VRU tests
• Configuration matrix covering seating positions, impact angles, speeds
• Alignment with NCAP, regulatory, and in-house performance criteria 

Crashworthiness Concept

Our Body-in-White design philosophy targets controlled deformation and occupant survival space integrity:

• Energy absorption zones in front, side, and rear impact areas
• Crash box geometry and section sizing for progressive collapse
• Material selection (Ultra-high-strength steels, press-hardened steels, aluminum alloys, composites)
• Finite element analysis for section thickness and joint optimization 

System Integration

We integrate restraint and protection systems into the vehicle architecture to meet crash targets:

• Harmonized deployment timing across multiple safety devices
• Mounting strategies and load path design for airbags and belts
• Structural reinforcement for sensor modules and active protection actuators

Verification & Correlation

We combine virtual and physical testing to validate our concepts:

• CAE simulations using LS-DYNA, PAM-CRASH, HyperWorks
• Virtual pedestrian/legform and headform impact models
• Prototype testing (Sled tests, full-vehicle crash tests, pedestrian subsystem tests)
• Correlation of CAE results with test data to refine simulation accuracy 

Modification & Design Update

Insights from verification drive refinements:
• Adjust airbag inflator parameters, belt pretensioner forces
• Modify BIW section dimensions and material grades
• Recalibrate sensor thresholds and actuator timings 

Detailed Design 

We finalize detailed designs and prepare for validation and type approval:
• Release of production-ready CAD models, drawings, and specifications