Certainly curtain air bags and seat belt pre-tensioners have been shown to save lives.
Your first paragraph also makes a number of claims, many of which I'm sure are true. Regardless it's an extraordinary claim, requiring evidence. Although admittedly in retrospect it could also be that the engineers are designing to the aforementioned tests. You also said that designers should, "Revise bumper and front/rear cosmetic design to allow for effective bumpers (see also: the 1980s) and tune crumple zones to need higher forces to deform them so you don't have to potentially replace a whole car over a 10-15mph collision." This strongly implies that the bumpers as they are currently designed are crumpling needlessly at low speeds, and that they could be made to not do so, like the bumpers of the 1980s, without compromising safety, hence that the engineers designing them are not competent. OK, you said, ".which is good for real world performance bad for scoring that perfect five stars in a low speed lab test that actually helps sell cars." This strongly implies that you believe the lab tests are not valid for their purported purpose of making cars safe, but are rather more of a marketing gimmick. The tradeoff here is that the speed range at which crumple zones do much would move up which is good for real world performance bad for scoring that perfect five stars in a low speed lab test that actually helps sell cars. Revise bumper and front/rear cosmetic design to allow for effective bumpers (see also: the 1980s) and tune crumple zones to need higher forces to deform them so you don't have to potentially replace a whole car over a 10-15mph collision. Secondly, it is perfectly possible to design cars that do not need tons of invasive repairs from minor fender benders. As a general rule, features that directly keep the occupants from hitting things are far more beneficial to outcomes than stuff that acts upon the whole vehicle. Pre-tensioners are also another feature that I'd rather have than a crumple zone. They save a lot more life and injury than crumple zones. If you want to worship something worship side curtain airbags. Crumple zones are undeserving of the worship they get. The speed window at which they will appreciably reduce the deceleration in the cabin is well below the speeds at which a seat-belted occupant of an airbag equipped vehicle has to worry about serious injury. Crumple zones perform a very specific function in the sequence of airbag deployment (letting the sensors crash and bags deploy before the cabin starts decelerating).
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