Geometrical changes can improve stiffness substantially. The project S3 - Safety Slim Shoe presents the potential to reduce the weight in safety toe cap components combining a new geometric redesign deeply associated to local stiffeners to realize the full potential of AHSS - Advanced High Strength Steels. The investigation aimed to examine the potential energy absorption capacity for a substantial thickness reduction of slim toe cap models. In this paper the normative quasi-static compression test in the context of the experimental validation of the two last and approved prototype models were focused. A non-linear FEA - Finite Element Analysis of the elasto-plastic deformation mode was performed, and several numerical parameters such as: hardening effects of extrapolated True-Stress-Strain material curves and simulation convergence conditions were carried out. Experimental results of the toe cap deformation behavior confront a weight saving range of over 40%, compared with the original steel toe cap. The safety footwear, in the context of the global evolution of footwear, has adopted creative and different orientations. Particularly, as an active element in the prevention of accidents fitted in PPE - Personal Protective Equipment, it is appropriate that its optimization solutions amplify the market targets, mainly combining ergonomic aspects, biological and mechanical features since its conception. The toe cap is the main component for its weight contribution, approx. 35% of total weight for each safety footwear model, and due normative context demands with high deformation resistance and impact loading (1). Currently the toe cap protection takes a subdivided position on design selection and materials, with a clear definition of two distinctive conception trends: metallic and non-metallic models. If on one hand the metallic models, especially high carbon steels with Heat Treatment processes, emphasize the security concept by the implicit mechanical strength performance, on the other hand, the weight of these solutions is a disadvantage compared to the metal-free solutions, and relegates the first one for outdated and heavier footwear concept. The non-metallic solutions with higher trend effects in the global market call on low density materials such as: reinforced Polyester composites with glass fiber, HDPE - High Strength Polyethylene, and several advanced developments in the optimization of energy