US Patent 8434230 Method to make a vehicle door

A vehicle door is manufactured by producing a supportive frame (10) and a waist rail (14) and a side impact guard beam (22) which are formed integrally with the supportive frame. The door is produced by hot stamping a steel sheet blank into the shape of a supportive door frame that includes an integral waist rail (14) and a side impact guard beam (22), and hardening the shaped door frame while the frame remains in the shaping tools, and fastening an outer panel (31) to the finished door such that the side collision guard beam (22) of the frame will lie close to the outer panel (31).