In response to the existing problems in evaluating the frontal compatibility of the UK’s Transport Research Laboratory (TRL) barrier, the design and development of a new type of frontal honeycomb aluminum barrier are proposed. Based on the key feature size data and stiffness curve of the vehicles, the theoretical stiffness extraction and appearance size design of the frontal collision honeycomb aluminum are carried out. Corresponding honeycomb aluminum samples are developed and verified by dynamic performance tests and vehicle crash tests. The test results show that the new frontal barrier solves the problem of evaluation distortion caused by TRL barrier breakdown. The structural characteristics and force distribution of the vehicle’s front end can be better identified. While evaluating crash compatibility, passenger protection performance can also be evaluated, providing reference data for the formulation of relevant evaluation protocols.