Increasing model variety,more vehicle customization and shorter innovation cycles have a strong impact on productivity and quality.The number of platforms and body types are permanently increasing inside a plant,leading to high tool and set-up costs in the body in white section of the factory.Moreover,as legislation sets mandatory emission reduction targets for new cars and trucks,new lightweight design strategies for the “Body-inWhite”(BIW)need to be found like ultra-high tensile materials with important springback and load optimized design of parts leading to complex geometries.Often parts of the BIW belong to a family differing only in a single geometrical parameter like overall length or width,or even only in material thickness.Hence,the companies tend to replace manufacturing processes like press forming due to their lack of flexibility by other more flexible production methods.We present a new manufacturing system using the sheet metal roll forming process to overcome many of these challenges.Traditional roll forming lines only produce parts with constant cross sections.A new 3D roll forming line for complex structural automotive parts opens new ways for production.It also gives more flexibility and higher product quality.In this study,an overview is given for possible families of parts being produced with this new production technique.The basic machine concept and its current application is shown.