The objective of this research was to minimize the pedestrian injury and to develop the optimized front bumper system prevent damaging the parts. The first approach was to draw out the undamaged conditions on FEM carrier through the RCAR CAE analysis. Then, it was proposed the pipe-type steel lower stiffener to maximize the space between FEM carrier and lower stiffener. Finally, the safety performances were verified in full vehicle test achieving the undamaged FEM Carrier (RCAR grade target satisfied) in low-speed crash and the perfect score six points in legform impact with newly designed parts. It was also investigated to minimize the impact space of the lower legform due to the design or packaging limitation. The optimum bumper energy absorber structural design was proposed using the steel instead of the current used EPP foam. The optimum design parameter of the system was defined by the DFSS method and the effects due to the design parameter were analyzed.