With the introduction of the new USNCAP protocols, which incorporated assessment of a 5th percentile occupant in the passenger seat, a variety of solutions were introduced to achieve 5 star accreditation using additional restraint solutions such as, but not exclusively, knee airbags, dual pretensioning and adaptive venting . The engineering challenge was to understand and design a passenger airbag system that recognized and adapted itself to the smaller, belted, 5th percentile female, while adequately restraining the larger, unbelted, 50th percentile male. In this paper we describe the development of an airbag restraint which achieves 5 star performance levels, where the design focus from the outset was to achieve minimal head, neck & chest injury risk. This was achieved without the need for active adaptive features. The CAE tools Madymo and Radioss were critical to the design of a new patented airbag which repeatedly demonstrated USNCAP RRS <=0.66.