A significant part of roll formed products is used as structural components and therefore subject of lightweight design. Load adapted cross-sections are an effective tool of realizing the lightweight idea. However, cross-sections of typical roll formed parts don’t change along the longitudinal direction. Instead, they are designed to withstand the maximum loads at critical points. Oversizing and material waste are the result of this. Flexible roll forming solves this problem by adding additional rotational and translational degrees of freedom to the roll forming stands. In doing so, roller positions may follow changes of the desired cross-section. A similar approach allows for the roll forming of blanks with variable thickness in the longitudinal direction, the so-called Tailor Rolled Blanks (TRB).