Body & Chassis

Division Overview

The Body and Chassis division is responsible for designing and manufacturing the vehicle’s structural backbone and driver environment, prioritizing ergonomics. The team designs and analyzes the frame and related safety systems to achieve high torsional stiffness, low weight, and compliance with Formula SAE rules. Manufacturing involves precise tube notching, welding, and integration of safety components. Testing focuses on verifying rigidity, driver ergonomics, and compatibility with other divisions such as Aerodynamics and Vehicle Dynamics. 

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Components

 

1. Frame 

   • Provides structural rigidity and crash protection. 

   • Divided into front, central, and rear sections, each serving safety and load-bearing purposes. 

   • Analyzed with FEA to validate torsional stiffness and crashworthiness. 

     
     

2. Pedal Box 

   • Ensures ergonomic pedal placement for different driver sizes. 

   • Designed for adjustability and direct feedback during braking/acceleration. 

   • Tested for durability and safety under repeated high loads. 

     
     

3. Seat 

   • Contoured for driver stability and comfort during high lateral forces. 

   • Mounted securely to the frame to distribute crash loads. 

   • Manufactured in lightweight composites for strength and weight reduction. 

     
     

4. Harness 

   • Keeps the driver firmly secured during operation and crashes. 

   • Must comply with FIA/FSAE standards for mounting points. 

   • Tested for proper installation angles and belt tension. 

5. Head Restraint 

   • Prevents excessive head movement in the event of impact. 

   • Positioned to align with driver height while meeting rulebook specs. 

   • Tested for load resistance under rearward force. 

     
     

6. Firewall 

   • Separates driver from high-voltage, fluids, and heat sources. 

   • Constructed with fire-resistant, insulated materials. 

   • Inspected to ensure complete sealing of the cockpit from hazards. 

     
     

7. Dashboard 

   • Provides the driver with critical performance and system data. 

   • Designed for visibility and accessibility without distraction. 

   • Integrated with low-voltage electronics and ECU. 

     
     

8. Steering Wheel 

   • Main driver control for vehicle handling and feedback. 

   • May integrate buttons for system control and data logging. 

   • Tested for ergonomics, strength, and durability under racing conditions. 

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Software 

• Computer-Aided Designs (CAD): SolidWorks 

• Computational Analysis (FEA/CFD): Ansys 

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Requirements

• INGE 3031: Applied Mechanics: Statics

• INGE 4019: Mechanics of Materials

• Proficiency in SolidWorks and ANSYS (FEA)

• Experience in manufacturing with composite materials

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Division Knowledge Guide 

Team members must distinguish between frame and chassis: the frame is the structural skeleton of the car, while the chassis includes additional mounting and body elements. The frame torsional stiffness is defined as the resistance of an object to twist or angularly deform when subjected to an external torque, and it affects handling and must be optimized through design iterations and FEA simulations. In manufacturing terms, notching and welding techniques are critical for a reliable joint, with CNC tools providing precision. The firewall is both a safety and design element, requiring heat-resistant materials and careful seating. One of the responsibilities Body and Chassis must prioritize is the driver’s high performance without compromising their comfort or rule compliance, which includes the seat, harness, pedal box, head restraint, steering wheel, and dashboard.  

Additionally, the division should be closely collaborating with the Vehicle Dynamics and Aerodynamics division. Mostly for the frame’s torsional stiffness, which directly affects the cornering balance and suspension response. Also, the frame must include a precise mounting position for wings and undertray integration. Poor alignment or inadequate stiffness in these regions can reduce aero effectiveness or cause structural issues.

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