The deadliest accident ratio for cars and trucks on highways occurs when vehicles are running underneath trucks, causing serious and even fatal injuries to the occupants of the vehicle. When heavyweight trucks collide with automobiles, passengers in the car are not shielded from potentially deadly injuries by the back safety shield's improper geometry. A Smart Rear Underrun Safety Shield (SRUSS) for rear impact and rear underrunning of hybrid passenger cars and heavy-duty trailers was created because of this work. According to testing conducted by the Vehicle Research and Development Establishment (VRDE), the current safety shield has higher distortion. Finite element analysis was used to model and test the cleverly adapted safety shield under Indian Standard 14812-2005 regulatory circumstances. Additionally, it was produced and tested internally with the same regulatory requirements. A certified testing setup was used to effectively confirm the safety shield. Through accreditation from the Automobile Research Association of India (ARAI) and real-world verification testing at VRDE, the performance of a proposed Smart Rear Underrun Safety Shield (SRUSS) for hybrid vehicles was examined. The results obtained have satisfied the road transport safety standards of the Indian Standard 14812-2005.