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Front under run protection device (FUPD) is a regulatory requirement for passive safety of N2 & N3 category vehicle. This device gives effective protection for small vehicles (M1 or N1 category) against under running of big vehicles (N2 & N3 category) in the event of a frontal collision. FUPD generally consists of the front under run protector (FUP) and its mounting structure. As the compliance load target for N3 category is high, the FUP required achieving regulation target need to have high rigidity. This increases its size and hence the weight, Increase in weight has impact on payload and cost. To curtail the weight of FUP, in general Aluminum with higher strength is in use, but use of Aluminum increases the cost. So the main challenge in FUPD design is to achieve the design with optimal system weight & cost.