Abstract: An energy management system for a vehicle which includes a bumper beam and at least one crush can made from composite materials. The crush can includes a plurality of portions, some portions are frangible and at least one is non-frangible. Bumper beam fixing apertures and vehicle fixing apertures pass through the non-frangible portion such that the crush can is connectable to the bumper beam and the vehicle via fixings which pass through at least one non-frangible portion. This ensures that the bumper beam remains attached to the vehicle in the event of a crash which causes the frangible portions to disintegrate.

Abstract: A method for making a crush can for a vehicle which has an internal moulded structure can include providing a crush can with a hole, filling the hole in the crush can with a fibre-reinforced material and compression moulding the fibre-reinforced material using the internal shape of the crush can as an outer shell of a split mould.