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By considering the crashworthiness design of bionic bumper structure during frontal impact, the thicknesses are chosen to analysis and optimal design to obtain the lightweight demand. The orthogonal experiment design and radial basis function are employed to construct the response surface for the performances of thin-xwalled components. The multi-objective cuckoo search (MOCS) is applied to perform the optimal design. The results demonstrate that the optimal method and process proposed have high accuracy and validity.