How do you design vehicle structure to perform well in small overlap frontal crashes?

Small overlap (25%) crash design challenges: Main rails miss the barrier, requiring alternative load paths. Strategies include: 1) Extended bumper beam with crush cans reaching outer corners; 2) Shotgun (upper rail) strengthening for direct engagement; 3) Wheel/tire deflection management to prevent intrusion; 4) A-pillar and hinge pillar reinforcement for maintaining door opening and protecting occupant space; 5) Rocker and floor structure for load distribution; 6) Restraint system timing adaptation for unique occupant kinematics (more lateral motion). Design must balance weight penalty versus existing frontal performance. CAE optimization explores multiple load paths, material grade combinations, and gauge distributions. Physical validation confirms structural mode and restraint effectiveness.