Hot Stamping Dies for Body Structural Parts

Hot Stamped Crash Box (Crash Can)

Crash boxes are sacrificial components mounted between the bumper beam and the body front structure. Hebei Haoxinran Machinery produces hot stamped crash boxes that are designed to crush predictably and absorb impact energy in low-to-moderate speed collisions, protecting the more expensive body structure from damage.

How Crash Boxes Work

A crash box is essentially a controlled deformation tube or box section. During impact:

• Progressive Folding: The crash box folds in a series of controlled accordion-like crushes, absorbing energy steadily over the crush distance.

• Sacrificial Design: After an accident, the crash box can be replaced rather than repairing the more expensive body rails and aprons.

• Low-Speed Protection: In impacts below approximately 15 km/h, the crash box absorbs all the energy, leaving the main body structure undamaged.

• High-Speed Support: In higher-speed impacts, the crash box fully crushes and then transfers remaining load to the body rails and bumper beam.

Hot Stamping Advantages for Crash Boxes

Using hot stamped ultra-high strength steel for crash boxes provides unique benefits:

• Higher Energy Absorption: The high strength-to-weight ratio of 1500MPa steel means more energy absorption per kilogram of material.

• Controlled Collapse: Material properties and geometric triggers (notches, beads) can be designed to ensure consistent crushing behavior.

• Space Efficiency: Smaller cross-section crash boxes can absorb the same energy as larger mild steel alternatives, saving packaging space.

• Predictable Performance: The consistent material properties from press hardening ensure crash performance is highly repeatable across production volumes.

Design Features

Our hot stamped crash box designs include:

• Rectangular or octagonal cross-section for stable crushing behavior

• Circumferential crush initiators at regular intervals to guide the folding pattern

• Mounting flanges for attachment to the bumper beam and body rails

• Optional bolted design for easy replacement after minor impacts

• Length and crush force calibrated to specific vehicle weight and impact speed requirements

Haoxinran develops crash box solutions that balance energy absorption performance, packaging efficiency, and repair cost objectives. We support both OEM bumper systems and aftermarket crash box replacement.