Abstract: A method includes forming a short version of a pillar reinforcement and a long version of the pillar reinforcement from a short blank and a long blank, respectively. The long blank includes a first portion and a second portion joined to the first portion. The method includes inserting the short blank into a first section of a cavity of a mold and compressing the short blank in the mold to shape the short blank. The method also includes inserting the long blank into the mold with the first portion positioned in the first section of the mold and compressing the long blank in the mold to shape the long blank. The same mold is used to form both the short blank and the long blank into the short version of a pillar reinforcement and a long version of the pillar reinforcement.

Abstract: A moonroof ring assembly may include a first portion being formed from a first material, and a second portion being laser welded to the first portion and being formed from a second material, wherein the first material is of a higher strength than the second material.

Abstract: A moonroof ring assembly may include a first portion being formed from a first material, and a second portion being laser welded to the first portion and being formed from a second material, wherein the first material is of a higher strength than the second material.

Abstract: A bumper and front rail assembly includes first and second front rails with a steel cross-member extending therebetween. The steel cross-member has a substantially U-shaped cross-section. A steel forward member is secured to the cross-member and spans the length thereof. The forward member is configured to act as a spring for elastic deformation against the cross-member in a low energy impact. First and second steel crush cans are disposed in the cross-member adjacent the first and second front rails, respectively. The crush cans are configured for improved energy management and can be used with or without the energy absorbing bumper system described.

Abstract: A bumper and front rail assembly includes first and second front rails with a steel cross-member extending therebetween. The steel cross-member has a substantially U-shaped cross-section. A steel forward member is secured to the cross-member and spans the length thereof. The forward member is configured to act as a spring for elastic deformation against the cross-member in a low energy impact. First and second steel crush cans are disposed in the cross-member adjacent the first and second front rails, respectively. The crush cans are configured for improved energy management.