Crushable polymeric rail extension, systems, and methods of making and using the same

A rail extension comprising:

• a base extending from one end of the rail extension, wherein the base includes vehicle rail attachments configured to attach to a vehicle rail;
• a front member configured for attachment to a bumper beam;
• a body extending from the base and toward the front member, wherein the base comprises cells formed by cell walls extending along at least a portion of a length of the body from the base toward the front member and forming cavities therethrough;
• open channels formed on each side of the body, wherein the open channels are defined by walls of adjacent cells;
• wherein the front member comprises a plurality of beam attachments that extend from the front member to the base;
• beam attachment inserts located within the beam attachments;
• and
• wherein a cross-sectional area of a cell varies from the front member to the base and wherein a thickness of at least a portion of the cell wall varies from the front member to the base.

A rail extension comprising:

• a base extending from one end of the rail extension, wherein the base includes vehicle rail attachments configured to attach to a vehicle rail;
• a front member configured for attachment to a bumper beam;
• a body extending from the base and toward the front member, wherein the base comprises cells formed by cell walls extending along at least a portion of a length of the body from the base toward the front member and forming cavities therethrough;
• open channels formed on each side of the body, wherein the open channels are defined by walls of adjacent cells;
• wherein the front member comprises a plurality of beam attachments that extend from the front member to the base;
• beam attachment inserts located within the beam attachments;
• and
• wherein the body comprises a crush initiator and wherein the body increases in cross-sectional area in a stepped geometry from the front member to the base.