Disclosed is a roll-formed closed section manufactured from a high strength aluminum alloy, such as, but not limited to, s701 T6, s650 T6, or other cold formable 7xxx alloys, depending on load requirements. The roll forming may occur in a soft state (F or T4) at room temperature. If higher formability is required, induction heating may be combined with roll forming. As shown in Fig. 1 below, the section is gradually formed to a closed shape resembling the Greek small letter Pi (p). Beams from this profile are well suited as door beams or Side Impact Beams (SIB), but may be used as any load-bearing beam, such as bumper beams or other structural reinforcements that limit intrusion in a crash.

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