Front Impact and Side Impact are the major cause of passenger injuries in car accidents. Passenger safety is the important criteria while designing the automotive Body In White (BIW). Side Door Intrusion Beam is one of the main energy absorbing part in event of side impact. This work focuses on comparative study of three cross-sectional profiles, three gauges and three materials for side door intrusion beam. A detailed numerical & experimental study has been performed to analyze the static and dynamic behavior of different cross section profiles, gauges & materials of side door intrusion beam in the event of side impact. Comparative study of side door intrusion beams has been made to find out the force reaction and energy absorption capacity of the beam to protect the occupant from the side collision by using FEA software. Taguchi method is used to determine the optimized design parameter by using static analysis of FEA model on three point bending simulations. Optimal design of side door intrusion beam with optimal energy absorbing capacity and resistance force is validated on three point bending experimental test. The Effectiveness of the optimal door beam design is verified on full vehicle side impact simulations. •This work focuses on comparative study of 3 cross-sectional profiles, 3 gauges and 3 materials for side door intrusion beam.•Taguchi method is used to optimized design parameter by using FEA model on three point bending simulations.•The Effectiveness of the optimal door beam design is verified on full vehicle side impact simulations.