O-EA tubing is a composite structure, made of aluminum and paper, that is being used for energy absorption and crash injury mitigation in automotive head impact, side impact and knee bolster applications. This paper describes the component testing, material/geometry characterization and the evolution of a finite element model of the O-EA tubing through a 3-Stage methodol- ogy. In the first part of he paper, a description of the O- EA tubing construction and the manufacturing process is Provided.
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