Tubular structure support with variable dimensions and mechanical properties

A structure support for a vehicle, comprising:

• a hollow metallic tube extending along a longitudinal axis and including two opposing ends, the tube defining an inner surface and a radially outer surface, wherein the tube is plastically deformed via mechanical forces to provide a plurality of plastically deformed sections disposed along the longitudinal axis, the plurality of plastically deformed sections including:
• a first section disposed at one end of the tube, the first section having a first inner diameter, a first outer diameter and a first wall thickness;
• a second section separated from the first section via a first transition zone, the second section having a second inner diameter, a second outer diameter and a second wall thickness;
• a third section remote from the first section and separated from the second section via a second transition zone, the third section having a third inner diameter, a third outer diameter and a third wall thickness;
• wherein the first wall thickness is greater than the second wall thickness and the third wall thickness, the second outer diameter is less than the first outer diameter and greater than the third outer diameter, and the third inner diameter is less than the second inner diameter and the first inner diameter;
• and
• wherein the third section has a strength greater than a strength of the second section.

A method of producing a tubular support, comprising:

• providing a hollow metallic blank defining an axis having a uniform initial wall thickness, a uniform initial inner diameter and a uniform initial outer diameter;
• forcing the blank through an orifice of an outer tool a first length to reduce the initial outer diameter and the initial wall thickness to a first outer diameter and a first wall thickness;
• forming a first transition zone by manipulating the blank with respect to the orifice of the outer tool to deform an outer surface of the blank radially inwards;
• advancing the blank through the orifice of the outer tool a second length to reduce the initial outer diameter and the initial wall thickness to a second outer diameter and a second wall thickness, the second outer diameter less than the first outer diameter;
• wherein forming the first transition zone by manipulating the blank with respect to the orifice of the outer tool includes pivoting the blank transversely to the axis and passing the blank obliquely through the orifice of the outer tool to transition from the first outer diameter to the second outer diameter;
• wherein the first transition zone is disposed between the first length and the second length.