Crashworthiness is a measure of the vehicle's structural ability to plastically deform and maintain sufficient survival space for the occupants in the event of an accident. The chassis members include progressive crush zones to absorb the crash kinetic energy. This paper investigates the effect experienced by the cross members of the chassis in rollover conditions by incorporating polymer ribbing inside the members. Polymer metal hybrid parts consist of an aluminum beam supported by ribbing or layers of polymer, which is a mixture of synthetic and natural resins. The metal provides the required strength and stiffness, while the polymer ribbing and layers provide the support necessary to prevent premature buckling without adding weight to the structure. Crash analysis is simulated using ANSYS workbench with various parameters and boundary conditions to analyze the effect on it in a crash environment. The results are optimized by using the ANOVA statistical analysis and regression equations are obtained for varying parameters. The structure can thus be modified by incorporating polymer metal hybrids, hence achieving a higher factor of safety. © 2015 by Begell House, Inc.