Chassis
Assembly & Manufacture
Assembly & ManufactureHome The aluminium monocoque was produced using a cut-and-fold process, a technique that transforms flat honeycomb sandwich panels into complex 3D structures. Each Larcore A20 panel was CNC-cut…
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Aluminium Monocoque Chassis
Aluminium Monocoque ChassisHome The 2025 chassis was designed as a cut-and-fold aluminium honeycomb monocoque bonded to a steel rear spaceframe. This hybrid structure combined the lightweight stiffness of a monocoque…
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Roll Hoops & Harness Bar
Roll Hoops & Harness BarHome Roll hoops and the harness bar were mounted using reinforced inserts and base plates within the monocoque, designed to meet FSUK rollover protection standards. The…
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Material Testing
Material Testings Home The aluminium honeycomb monocoque was validated against FSUK SES requirements through physical testing. Three-point bending showed panel stiffness above the T45 steel baseline, confirming equivalent flexural performance.…
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Welding & Assembly Fixtures
Welding & Assembly FixturesHome Custom fixtures were built to ensure accuracy during chassis manufacture. The monocoque was folded and bonded in CNC-cut MDF jigs that controlled panel angles within ±0.5°.…
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Close-out Panels
Close-out PanelsHome Created carbon fibre panels secured to the lower tubes of the chassis to provide driver protection. These not only serve as safety barriers (guarding against debris, tubing ends,…
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Spaceframe Chassis
Spaceframe ChassisHome This spaceframe represented the most significant departure from Staffordshire Uni Racing’s previous designs, incorporating major changes in geometry, load paths, and manufacturing detail. Built from T45 steel tubing,…
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Welding Fixture
Welding FixtureHome Constructed from 12 mm MDF with routered geometry. This ensured repeatable alignment for welded assemblies, reducing distortion and improving weld consistency. Categories Spaceframe Tags Formula Student
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Tabs and Brackets
Tabs and BracketsHome Custom-designed and manufactured in-house to attach every ancillary component to the chassis. These weld-on tabs and brackets were engineered to disperse loads, simplify assembly, and allow future…
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