Impact absorbing structures and methods of manufacturing

A vehicle anti-intrusion beam, comprising:

• a multi-layer composite structure including:
• a first fibrous material having a first effective elastic modulus, the first fibrous material comprising one or more layers comprising fibers of a first type being arranged with one or more orientation angles having absolute values in a range of between 1° and 45° relative to a central longitudinal axis of the beam, such that a predetermined load applied to the beam from a direction perpendicular to the central longitudinal axis thereof drives the fibers of the first type towards alignment with the central longitudinal axis of the beam, the alignment of the fibers of the first type being responsible for absorbing a first portion of impact energy of the predetermined load;
• and
• a second fibrous material having a second effective elastic modulus, the second fibrous material comprising one or more layers comprising fibers of a second type, the second fibrous material having elongation property that provides effective elongation or deformation of the beam which prevents splitting of the beam under application of the predetermined load,
• wherein a cross section of the vehicle anti-intrusion beam is hollow, and wherein an innermost layer of the vehicle anti-intrusion beam defines the hollow and is formed of at least one of the first fibrous material or the second fibrous material, the composite structure is formed of the fibrous material and resin extending across an entirety of each wall of the beam and providing impact resistance to the entire width of each side of the beam.