Integrated structural member for a vehicle and method of making

A method for forming an integrated structural system for a vehicle, the method comprising:

• forming a structural member by securing a first structural member to a second structural member, the first structural member having higher mechanical properties than the second structural member;
• inserting the structural member into a mold cavity;
• securing a first beam component to the structural member by a molding process, the first beam component being molded from a thermoplastic material inserted into the mold cavity;
• removing the structural member from the mold cavity;
• and
• securing a second beam component to the first beam component, the second beam component being separately molded from a thermoplastic material, the second beam component having a configuration different from the first beam component.

An integrated structural system for a vehicle, comprising:

• a structural member;
• a first beam component secured to the structural member by a molding process, the first beam component being molded from a thermoplastic material;
• and
• a second beam component secured to the first beam component after the first beam component is molded to the structural member, the second beam component being separately molded from a thermoplastic material, and the second beam component having a configuration different from the first beam component.