The vehicle bonnet assembly is a key structural element in a vehicle assembly in terms of vulnerable road users (VRU) safety. As the design and development of a bonnet is becoming more difficult because of the contradictory requirements, due to the current homologation process. On one hand the bonnet must be stiff enough to withstand loads and be durable during the lifecycle of the vehicle, while it also must be soft enough to provide energy absorption in case of a pedestrian collision. The thesis project was developed starting from the concept car bonnet design made of carbon fibre, redesigning to an aluminum bonnet for low volume production to achieve different design requirements that include regulations, manufacturability, and style - as the bonnet is an exterior class A surface, the quality and aesthetic appeal of the component is important.