Abstract Within the study’s scope, impact analyses of homogeneous bumper beam-crash box systems designed from AA6063-O, AA6063-T5, and AA6063-T6 materials and hybrid systems designed from combinations of these materials were made and compared in terms of energy absorption values. In designs where failure does not occur, the highest energy absorption value was obtained using the AA6063-T5 bumper beam and AA6063-O crash box system, and single and multi-objective optimization studies were conducted using this design. The optimal bumper system improved the crash performance of the structure. Accordingly, this bumper system can be used in vehicles to improve crashworthiness.