Crashworthiness of a material is a measure of its ability to absorb energy during a crash. A well-designed crash box is instrumental in protecting the costly vehicle components. A square, hollow, hybrid beam of aluminum/CFRP was subjected to dynamic axial load to analyze the effect of five different lay-up sequences on its crashworthiness. The beam was placed between two plates. Boundary conditions were imposed on them to simulate a frontal body crash test model. Modeling and dynamic analysis of composite structures was done on ABAQUS. Different orientation of carbon fibers varies the crashworthiness of the hybrid beam. Addition of CFRP layer showed clear improvement in specific energy absorption and crush force efficiency compared to pure aluminum beam. Two layers of CFRP oriented at 90° on Aluminum showed 52% increase in CFE. © 2017 Published under licence by IOP Publishing Ltd.