Success Stories

Numerous vehicles  take advantage of the attributes of aluminum extrusions to produce lightweight, safe and economical bumper reinforcement beams and crash cans. In addition to the vehicles below, extruded bumpers can be found on Honda’s Civic, CRV and MDX; the Kia Sorento & Optima; Hyundai Sonata & IONIQ 5 EV; Chevy Camaro, Toyota Tacoma, and others. Select the vehicle below to learn more.

2021 Toyota Tundra

Crash Management: Extruded Aluminum Bumper Beam 

2022 Tesla Model Y

Crash Management: Extruded Aluminum Crush Cans & Rear Bumper Beam 

See Tesla's description of Model Y crash safety on YouTube.

2022 Lucid Air

Aluminum-Intensive Body Structure & Crash Protection

  • Extruded Rails 
  • As well as other extrusions not visible here, including rocker & roof bow

2022 Fisker Ocean

Extruded Elements

  • Hood support
  • Aluminum Skateboard Extruded Rails

2022 Honda Pilot

Extruded Elements

  • Front Bumper assembly also used on 2020 Acura RDX and Honda Odyssey
  • Assembly includes welding & mechanical fasteners


2021 Ford Mustang Mach-E

Despite a steel-intensive BIW, and a vehicle weight that is 36% heavier with 10% less crash space, an aluminum extruded bumper and crash cans offered the best business case.

2021 Acura TLX

The Acura TLX uses 6000-Series Aluminum Front (and Rear) Bumpers


  • 2020 IIHS Top Safety Pick
  • NHTSA 5-Star Overall Vehicle Score

2019 Acura RDX 

The vehicle features aluminum extruded bumpers on steel-intensive body structure. The front includes crash cans, and the rear features additional extrusions. 

2020 Honda Accord

Reinforcement for good small offset reinforced barrier (SORB) test results

2020 Ford Explorer

Bumper reinforcement, presumable for small offset reinforced barrier (SORB) protection 

Front bumper, crash can, and backing plate extruded materials 

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