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The objective of this paper is to discuss the process, from design conception through analytical simulation to experimental test, of the development of a composite cross car beam for a passenger vehicle application. Over the past five years there has been considerable interest in the development of cross car beams, which serve as the main component for support of the Instrument Panel (I/P) structure and related systems. Stringent design requirements for vehicle Noise, Vibration and Harshness (NVH), durability and crashworthiness have driven the role of cross car beams to new levels. In addition, new styling trends, such as cabin forward design, and new vehicle manufacturing and assembly methods, such as cockpit build, have also placed demands on the role of cross car beams.