Vehicle front rail

A structural beam for a vehicle, the structural beam comprising:

• an elongated body formed from a single metal sheet and configured to extend from a first end at a bumper assembly to a second end at a mid-frame assembly, the elongated body having a cross-sectional shape that extends a length of the elongated body;
• wherein the cross-sectional shape of the elongated body includes a first side wall, a second side wall, a top wall, a bottom wall, and a central wall extending between the first and second side walls,
• wherein the elongated body includes two hollow channels divided by the central wall formed by the single metal sheet, and
• wherein the central wall, the first side wall, the second side wall, the top wall, and the bottom wall are together formed by the single metal sheet.

A front rail configured to be supported by a vehicle frame, the front rail comprising:

• a tubular body formed by a single, high-strength metal sheet and defining a cross-sectional shape along a length of the tubular body;
• wherein the cross-sectional shape includes a first side wall, a second side wall, a top wall, a bottom wall, and a central wall extending from the first side wall to the second side wall of the tubular body defining a first longitudinal hollow channel and a second longitudinal hollow channel on opposing sides of the central wall;
• wherein a groove is disposed in the first side wall of the tubular body and extending longitudinally in the length of the tubular body;
• and
• wherein the tubular body is configured to undergo axial loading during a frontal vehicle impact.