ATV All-Terrain Vehicle Chassis & Bodywork

Client PartnerApex Motorsport R&D

Technology5-Axis VMC Milling

Material GradeChromoly Steel (AISI 4130) & Carbon Fiber

Turnaround Time14 Working Days

ATV All-Terrain Vehicle Chassis & Bodywork High Precision Spec

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Project Execution & Background

Client Objectives & Background

Apex Motorsport R&D needed a high-performance spaceframe chassis capable of surviving 5G impact tests during off-road trials while shedding 15% overall vehicle weight to gain a competitive edge.

Design & Prototyping Methodology

Our team conducted FEA stress analysis in SolidWorks Simulation to optimize tubing wall thickness. Tubing profiles were laser-notched and fixture-welded using TIG welding setups followed by 5-axis VMC machining of suspension mounting tabs.

Quality Control & Inspection Protocol

Every weld seam underwent non-destructive ultrasonic testing, and hard points were verified using 3D laser metrology scanning to guarantee 0.05mm alignment squareness.

Engineering Specifications Table

Engineering Parameter	Specification & Standard
Tolerance	±0.05 mm (Laser Notch & VMC Fit)
Material Grade	Chromoly Steel AISI 4130 & Carbon Fiber
Tensile Strength	670 MPa Yield Strength
Surface Finish	Powder Coated Matte Finish (ISO 2409)
Quality Inspection	Ultrasonic Weld Inspection & CMM Probe
Standards Compliance	SAE Baja & FIA Roll Cage Compliance
Production Volume	5 Prototype Racing Frames

The Challenge

The client required a roll-cage frame capable of absorbing extreme impact forces during high-speed off-road trials while reducing vehicle weight without structural deformation.

Engineering Solution

Constructed the chassis using precision-notched Chromoly steel tubing, optimized gusset plates, and custom 5-axis CNC milled aircraft-grade aluminum mounting brackets.