A variable thickness roll forming system for forming a variable thickness blank from a metal sheet passing through at least two sets of rollers, the roll forming system comprising: - at least two sets of cylindrical shaped rollers, each of the at least two sets of rollers including: ∘ a first roller including a face which is linear where the first roller is adapted to contact the metal sheet; and ∘ a second roller including multiple shaping faces positioned about a perimeter and directed toward the face of the first roller; - each of the at least two sets of rollers adapted to incrementally alter a thickness of the metal sheet in at least a direction transverse to a feed direction (18, 122) of the metal sheet when the metal sheet is passed between the first roller and the second roller; wherein the first roller and the second roller are adapted to form a roll formed blank having a first portion and at least a second portion positioned in the direction transverse to the feed direction (18, 122) of the metal sheet with respect to the first portion, the first portion having a thickness greater than a thickness of the second portion, characterized in that the variable thickness roll forming system includes a translational roller (80, 106, 108) positioned between a first roller set (82, 110) of the multiple roller sets and a second roller set (84, 112) of the multiple roller sets, said translational roller (80, 106, 108) being adapted to be displaced in a displacement direction (100, 126,128) substantially transverse to the metal sheet and toward the metal sheet to lengthen the metal sheet between the first roller set (82, 110) and the second roller set (84, 112). - at least two sets of cylindrical shaped rollers, each of the at least two sets of rollers including: ∘ a first roller including a face which is linear where the first roller is adapted to contact the metal sheet; and ∘ a second roller including multiple shaping faces positioned about a perimeter and directed toward the face of the first roller; ∘ a first roller including a face which is linear where the first roller is adapted to contact the metal sheet; and ∘ a second roller including multiple shaping faces positioned about a perimeter and directed toward the face of the first roller; - each of the at least two sets of rollers adapted to incrementally alter a thickness of the metal sheet in at least a direction transverse to a feed direction (18, 122) of the metal sheet when the metal sheet is passed between the first roller and the second roller; wherein the first roller and the second roller are adapted to form a roll formed blank having a first portion and at least a second portion positioned in the direction transverse to the feed direction (18, 122) of the metal sheet with respect to the first portion, the first portion having a thickness greater than a thickness of the second portion, characterized in that the variable thickness roll forming system includes a translational roller (80, 106, 108) positioned between a first roller set (82, 110) of the multiple roller sets and a second roller set (84, 112) of the multiple roller sets, said translational roller (80, 106, 108) being adapted to be displaced in a displacement direction (100, 126,128) substantially transverse to the metal sheet and toward the metal sheet to lengthen the metal sheet between the first roller set (82, 110) and the second roller set (84, 112). wherein the first roller and the second roller are adapted to form a roll formed blank having a first portion and at least a second portion positioned in the direction transverse to the feed direction (18, 122) of the metal sheet with respect to the first portion, the first portion having a thickness greater than a thickness of the second portion, characterized in that the variable thickness roll forming system includes a translational roller (80, 106, 108) positioned between a first roller set (82, 110) of the multiple roller sets and a second roller set (84, 112) of the multiple roller sets, said translational roller (80, 106, 108) being adapted to be displaced in a displacement direction (100, 126,128) substantially transverse to the metal sheet and toward the metal sheet to lengthen the metal sheet between the first roller set (82, 110) and the second roller set (84, 112).