Until now, passenger airbag design is based on the referred car design and many repetitive crash tests have been done to meet the crash performance. In this paper, it was suggested a new design process of passenger airbag. First, key performance factors were determined by analyzing the injury risk effectiveness of each performance factor. And it was made a relationship between injury risk and performance factor by using the response surface model. By using this one, it can be predicted the injury risk of head and neck. Predicted injury risk of optimal design was obtained through this injury risk prediction model and it was verified by FE analysis result within 18% error of head and 9% error of neck. It was shown that a target crash performance can be met by controlling the key performance factors only.