Modular multi-material crash-box for tailored impact energy absorption during low-speed collision (PROTECT)

Low-speed (20 mph) accidents saw year-on-year increase of 31% (2016-2017, Department of Transport); injury increase was broken down as fatal (+79%), serious (+47%), and slight (+42%). A crash box is a thin-walled structure attached between the vehicle bumper structure and the side rail to improve crash performance in low-speed accidents. The determination of the crash box geometry is important to absorb the impact energy, since the installation space of the crash box is not very large. Conventional crash boxes (i.e. those manufactured from steel or aluminium) exhibit high-peak force and have no way of controlling the rate of deceleration following a crash. Composite alternatives are limited in use due to unpredictable failure.

PROTECT is an innovative new crash-box with better impact energy-absorption capabilities; enabling minimal damage to the vehicle itself, its occupants, and other road users. In the event of a low-speed collision, PROTECT will help reduce damage to the vehicle, its occupants and the wider public. This will result in safer roads and vehicles, along with minimised repair costs. As a result of this innovative solution, the consortium partners expect to create 227 jobs and generate cumulative revenues of £51.6 million by 2029\.