An anti-intrusion beam for incorporation into a vehicle door assembly is manufactured from an outer skin formed from laminated layers of composite materials having fiber reinforcement oriented in a directional pattern in each respective layer. The anisotropic beam includes body members having an interior core formed of high density foam plastic. The transversely corrugated beam includes attachment areas that have the same corrugated configuration which are fastened to mounting lugs of an inner door panel arranged in a corresponding corrugation. Variations in the thickness and formation of the layers of the outer skin can be used to control the failure of the beam during impact to provide a progressive predicable failure pattern for the beam. A frame catcher can be inserted into the body portions of the anti-intrusion beam to permit the transfer of impact forces to the frame of the vehicle.