Abstract: A rocker assembly includes a rocker reinforcement panel attached to a side inner panel to define a cavity and an elongated bar disposed within the cavity. The elongated bar is formed of a polymer resin that includes reinforcement strands of continuous fiber roving that are embedded in the polymer resin and extend along a full length of the bar. The elongated bar has a constant cross-section perpendicular to the length of the bar that may define at least one elongated opening. A method of making a rocker assembly includes pultruding a polymer resin and a continuous fiber roving to form a reinforced elongated bar that is assembled into a cavity defined between the rocker reinforcement panel and the side inner panel.

Abstract: A rocker assembly includes a rocker reinforcement panel attached to a side inner panel to define a cavity and an elongated bar disposed within the cavity. The elongated bar is formed of a polymer resin that includes reinforcement strands of continuous fiber roving that are embedded in the polymer resin and extend along a full length of the bar. The elongated bar has a constant cross-section perpendicular to the length of the bar that may defines at least one elongated opening. A method of making a rocker assembly includes pultruding a polymer resin and a continuous fiber roving to form a reinforced elongated bar that is assembled into a cavity defined between the rocker reinforcement panel and the side inner panel.

Abstract: A hydroform tube includes a first end and a second end. The hydroform tube includes a plurality of sides including a first side and a second side, and a fillet extending from the first side to the second side. The first side, the second side, and the fillet extend from the first end to the second end. The plurality of sides form different shapes at two cross-sections between the first end and the second end. The tube has substantially the same perimeter P at all cross-sections from the first end to the second end. The fillet has a radius R. The radius R is defined by a same formula at all cross-sections from the first end to the second end.

Abstract: A method includes extruding an elongate member that has a longitudinally extending cross section, bending the elongate member about a first axis and subsequently about a second axis, non-parallel to the first axis, to form a vehicle body component.

Abstract: A hydroform tube includes a first end and a second end. The hydroform tube includes a plurality of sides including a first side and a second side, and a fillet extending from the first side to the second side. The first side, the second side, and the fillet extend from the first end to the second end. The plurality of sides form different shapes at two cross-sections between the first end and the second end. The tube has substantially the same perimeter P at all cross-sections from the first end to the second end. The fillet has a radius R. The radius R is defined by a same formula at all cross-sections from the first end to the second end.

Abstract: A vehicle body component is provided. The vehicle body component includes an extruded elongate member that has a longitudinally extending cross section. The elongate member includes a first section that extends along a first axis, a second section that extends from the first section along a second axis, and a third section that extends from the second section along a third axis, wherein the first axis and the third axis are non-coplanar with respect to each other.

Abstract: A vehicle body component is provided. The vehicle body component includes an extruded elongate member that has a longitudinally extending cross section. The elongate member includes a first section that extends along a first axis, a second section that extends from the first section along a second axis, and a third section that extends from the second section along a third axis, wherein the first axis and the third axis are non-coplanar with respect to each other.