A high strength dual-swaged airbag inflator vessel comprising a high strength metal material, such as low carbon steel, has a swaged terminal end defining two distinct swaged portions. A reduction of diameter within one of the swaged portions is restricted to be less than or equal to about 30% and in certain variations, less than or equal to about 16% to minimize cold work strain hardening and to reduce loss of ductility. In certain aspects, a second swaged portion within the swaged terminal end has a length of less than or equal to about 10 mm. Methods for making such a dual-swaged airbag inflator vessel are likewise provided. Such dual swage designs have improved reliability and performance in high pressure inflator applications, as well as reduced manufacturing costs.