Abstract: An energy absorbing system includes a carrier having a wall extending along a longitudinal axis. The energy absorber has a first leg and a second leg extending in a first direction away from the wall. A plurality of fins are fixed to and extend from the wall in the first direction, at approximately 60 to 65 degrees relative to the wall.

Abstract: An energy absorbing system includes a carrier having a wall extending along a longitudinal axis. The energy absorber has a first leg and a second leg extending in a first direction away from the wall. A plurality of fins are fixed to and extend from the wall in the first direction, at approximately 60 to 65 degrees relative to the wall.

Abstract: A vehicle front-end stiffener includes a hinge bracket pivotally coupled to a support bracket. The hinge bracket supports a stiffener beam. A spring engages the support bracket and the hinge bracket biasing the stiffener beam in a deployed position. A moving element in a locking mechanism can retractably interlock the hinge bracket when a vehicle exceeds a threshold speed to maintain the stiffener beam in the deployed position.

Abstract: A method of adjusting a stamping die is provided. The method includes providing a two-sided stamping die configured to form parts from sheet metal blanks according to a desired geometry upon closing the die, adjusting the desired geometry of the part, and repeatedly depositing layer upon layer of material onto a first side of the die in a stacked configuration to modify the geometry of the first side of the die such that the die forms parts from sheet metal blanks according to the adjusted desired geometry.

Abstract: A bumper assembly includes a bumper beam, an actuator, and a lower stiffener. The actuator includes a base mounted to the bumper beam, and a rod moveably engaged with the base along a vertical axis. The lower stiffener is fixed to the rod. Depending on pre-determined vehicle speeds, the lower stiffener moves from a deployed position to a retracted position based on pedestrian leg impact considerations and to reduce the likelihood of lower stiffener damage.

Abstract: A bumper assembly includes an elongated beam and a pair of crush cans. The elongated beam includes a plurality of reinforcing walls extending horizontally that define a gap in a central portion of the beam. The pair of crush can assemblies is attached to the beam at transversely spaced locations relative to the central portion of the beam. The central portion of the beam is structured to have less bending resistance than the right and left sides. The reinforcing walls span the crush can assemblies so that the gap facilitates bending the central portion of the beam. A method of making a bumper is also disclosed that includes the steps of selecting a bumper beam and partially removing an upper/central portion and a lower/central portion of the bumper beam.

Abstract: A bumper assembly includes an elongated beam and a pair of crush cans. The elongated beam includes a plurality of reinforcing walls extending horizontally that define a gap in a central portion of the beam. The pair of crush can assemblies is attached to the beam at transversely spaced locations relative to the central portion of the beam. The central portion of the beam is structured to have less bending resistance than the right and left sides. The reinforcing walls span the crush can assemblies so that the gap facilitates bending the central portion of the beam. A method of making a bumper is also disclosed that includes the steps of selecting a bumper beam and partially removing an upper/central portion and a lower/central portion of the bumper beam.

Abstract: A vehicle front-end stiffener includes a hinge bracket pivotally coupled to a support bracket. The hinge bracket supports a stiffener beam. A spring engages the support bracket and the hinge bracket biasing the stiffener beam in a deployed position. A moving element in a locking mechanism can retractably interlock the hinge bracket when a vehicle exceeds a threshold speed to maintain the stiffener beam in the deployed position.

Abstract: An automotive armrest includes an elastic core defining a patterned array of channels extending therethrough such that the elastic core exhibits a predetermined target vertical stiffness and a predetermined target lateral stiffness different than the predetermined target vertical stiffness. The automotive armrest also includes a skin arranged with the elastic core.

Abstract: A vehicle includes a chassis having a pair of rails spaced from each other and a deployable reinforcing device extending between the rails. The deployable reinforcing device includes a beam disposed between the pair of rails and including walls and hinges connected in alternating arrangement. The walls are rotatable about the hinges from a collapsed position to an expanded position. The device includes a deployment mechanism disposed between the walls. When a vehicle impact is sensed, the deployment mechanism is deployed to expand the beam to the expanded position to reinforce the rails.

Abstract: An airbag system includes an airbag. The airbag includes a face portion configured such that when the airbag is inflated; the face portion forms a corrugated section. The corrugated section has a plurality of corrugations. The plurality of corrugations is configured to impede movement of an occupant's head from a center of the airbag toward a side of the airbag during impact. The plurality of corrugations is formed using a plurality of tethers attached to the face portion.

Abstract: A vehicle chassis includes a pair of rails spaced from each other. A beam is disposed between the pair of rails and defines a cavity. The beam includes walls and hinges connected in alternating arrangement about the cavity. Each hinge is connected to two of the walls. A wedge is disposed between one of the rails and the beam adjacent the cavity for driving the walls and hinges toward an expanded position during a side impact.

Abstract: A system includes an injector including a robotic arm and a heated chamber. The injector includes a material feed and a heating element. The robotic arm is arranged to deposit the material feed onto a vehicle component in the heated chamber.

Abstract: A vehicle includes a floor and an aluminum battery enclosure. The enclosure has L-shaped formed side walls each at least partially defining a traction battery cavity and including a foot attached to the floor. Each of the feet extends an entire length of the corresponding side wall to distribute impact energy along the entire length to maintain a relative position between the floor and enclosure.

Abstract: A bumper assembly includes a bumper beam, an actuator, and a lower stiffener. The actuator includes a base mounted to the bumper beam, and a rod moveably engaged with the base along a vertical axis. The lower stiffener is fixed to the rod. Depending on pre-determined vehicle speeds, the lower stiffener moves from a deployed position to a retracted position based on pedestrian leg impact considerations and to reduce the likelihood of lower stiffener damage.

Abstract: A vehicle includes a floor and an aluminum battery enclosure. The enclosure has L-shaped formed side walls each at least partially defining a traction battery cavity and including a foot attached to the floor. Each of the feet extends an entire length of the corresponding side wall to distribute impact energy along the entire length to maintain a relative position between the floor and enclosure.

Abstract: A hybrid expandable restraint volume enclosure system incorporating at least one deployable semi-rigid human body reaction surface is provided. One or more walls of the expanding volume are substantially pliable, attaching at one end to a mounting base that is attachable to a structural member of a vehicle and another end attached to a semi-rigid deployable reaction surface. The energy absorbing expansion member may be thin walled or membrane-like and comprised of pliable rubber, plastic or a woven fabric. Methods of attaching a flexible expansion member to either a semi-rigid contact surface or a semi-rigid expansion wall of the enclosure include providing a mechanical attachment by capturing an expansion member edge between a frame and semi-rigid member. Material from a molded semi-rigid member may flow over or into geometries provided in a flexible expansion member for joining. An interface may be defined by blend-molding to transition different material stiffness.

Abstract: A crush-can is provided. That crush-can includes a first wall, a second wall within the first wall and a corrugated core between the first wall and the second wall. A method for producing the crush-can via 3D printing is also disclosed.

Abstract: A crush can to an automotive vehicle has a twelve-cornered cross section comprising sides and corners creating internal angles and external angles. A geometry of the cross section varies between a front section and a rear section of the crush can. The geometry of the cross section is optimized using a plurality of control parameters including a lateral width, a vertical width, a taper ratio, a front scaling factor, and a rear scaling factor.

Abstract: An airbag system includes an inflator and an airbag in communication with the inflator. The airbag system includes a tether actuator and tethers extending from the tether actuator to the airbag. A controller is programmed to receive signals from an impact sensing system and a steering wheel angle sensor. The controller is programmed to instruct the tether actuator to release at least one of the tethers based at least on the signals from the steering wheel angle sensor and the impact sensing system.