Recently, the application and development of knee airbag module into the vehicle are increasing to achieve a good rating during EuroNCAP and IIHS test. Also, EuroNCAP and IIHS press the automotive company to equip knee airbag module to improve occupant knee injury and give some benefit regarding knee airbag equipped vehicles at barrier test. (1) Therefore, the invisible knee airbag module has been independently developed through design, simulation, static deployment test and knee impact test. But it was very difficult to position the knee cushion in case of short space between IP lower panel and knee surface. To overcome this problem and optimize knee airbag cushion shape, DOE (Design Of Experimental) method has been applied on knee airbag cushion folding methodology and cushion inner shape using by blow test. But it was presented just knee airbag folding DOE in this paper and verification test results are presented.

A good relationship between DOE result and previous study (=trial & error method) for knee airbag folding process has been found in this study.