In this paper the elasto-plastic behavior of the toe cap safety footwear component for three different Advanced High Strength Steels (AHSS) combined with new geometric models, was analyzed. The normative quasi-static compression test in the context of the experimental validation of different prototypes, and the conceptual orientation of those models with numerical simulation were performed. The study aimed to examine the potential energy absorption capacity for a substantial thickness reduction of slim toe cap models. A non-linear Finite Element Analysis of the plastic deformation mode with material properties as strain hardening of True-Stress-Strain extrapolated curves was considered. From experimental results it was found that the evolved geometric model had significant influence on the static stiffness and toe cap damage for a weight saving range of approx. 35 to 40%, compared with the original steel toe cap.

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