As the world automotive crash safety regulations are different, it’s very important to design the energy
absorbing structures that satisfy different collision boundary conditions. A large number of vehicle energy absorption
beams dimensions were measured and then a common thin-walled rail was chosen. Considering the complexity of
automobile collision boundary, finite element analysis and experimental design, interval uncertain algorithms, Kriging
approximate model, NSGA - II genetic algorithm were combined to optimize the structure of the thin-walled rail with
different impact velocity and different impact angle. Then the Pareto optimal solution was obtained. Thin walled beam
after optimization has good energy absorption characteristics under different collision boundary conditions. Research
results provide a method for the designing of a car that meets various crash regulations at the same time.