The airbag is an occupant protection device widely used in the automotive industry. Federal Motor Vehicle Safety Standard 208 requires the low-risk deployment airbag system to be utilized in vehicles to protect out-of-position occupants. This paper presents a design-for-six-sigma low-risk deployment passenger airbag optimized by adding a passenger protection wrap. The passenger protection wrap reduces the cushion impact force on the passenger by ensuring pressure dispersion. A series of static tests were conducted to demonstrate the proposed system using Federal Motor Vehicle Safety Standard 208 test procedures. The test results shows that the proposed passenger airbag satisfies the criteria established by Federal Motor Vehicle Safety Standard 208 and also presents a significant improvement over conventional airbag systems.