This paper presents crashworthiness design for thin-walled tubes with circular cross sections, including straight and curved tubes, which are used as energy-absorbing devices. Optimised designs of the circular cross sectional profile for both straight and curved thin-walled tubes are obtained to maximise such tubes' crushing performance. The optimisation process is carried out by using the design of experiments method (DOE) and finite element analysis (FEA). Crash behaviour of both straight and curved tubes is investigated and the effects of the circular cross sections on the structures' crushing performance are analysed through a parametric study. In this paper, a comparatively new but efficient FEA model, simplified model, is used for this design project. It is validated that compared to the detailed FE model, the simplified model can well be used for the product design problem while saving much more modelling labour and computer resources.