A structural door beam for vehicles, and a method for making the same, is provided. The structural door beam has an elongate multiple channel structure defined by a central web of given thickness and known material composition, and includes end mounting-flanges integrally formed therewith. The elongate multiple channel structure comprises two outer channels separated one from the other in a lateral direction, and a third channel disposed between the two outer channels. The third channel defines a trough within the medial region between the two outer channels. A first one of the two outer channels is drawn to a peak of known height and the trough is drawn to a known depth, such that the trough to peak distance exceeds a maximum distance that is achievable in a single cold forming operation for the given thickness and material composition of the web.