There have not been many studies on the factors that affect chest deflection, although the US NCAP thoracic injury criterion was recently shifted from the 3-msec clip to chest deflection. This study explored these factors and proposed a design methodology for the factors to minimize chest deflection. Because injuries can become severe if the driver crashes against the vehicle interior, this study also sought a solution using a penalty function to prevent crashes with the interior and minimize injuries. First, a MADYMO model was made to simulate US NCAP and EURO NCAP tests by one-to-one and stochastic verifications. Second, a sensitivity analysis was conducted to find the major factors that affect chest deflection. Lastly, the factors identified via the sensitivity analysis were optimized to propose design guidelines that helped vehicles receive high star ratings in US NCAP and EURO NCAP tests and helped minimize the possibility of hard contact between the driver and the vehicle interior by utilizing a penalty function and the Taguchi method.