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Could anyone design/engineer plans for Carbon Fiber Tub / Monocoque Chassis?

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  • Could anyone design/engineer plans for Carbon Fiber Tub / Monocoque Chassis?

    Is anyone here able to (or refer me to someone who can) design and engineer a carbon fiber tub or monocoque chassis? I'd like to purchase plans or 3d CAD file complete with FEA and layup schedules. Thanks

  • #2
    Dr, unless you have access to a very large autoclave you will be just as well off building a tube and sheet metal modular tub. From my understanding of this the strength of the curing process under vacuum and high heat is what makes the carbon fiber suitable for a monocoque tub.

    Good luck with your endeavor though!

    Mike

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    • #3
      I don't think you grasp how expensive such technology is.

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      • #4
        Originally posted by onewickedsvt View Post
        I don't think you grasp how expensive such technology is.
        .....I didn't say that I wanted that machine...I only referenced it because of the lack of use of an autoclave
        Last edited by doctor bombeii; 04-10-2014, 08:45 AM.

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        • #5
          I think your overlooking something ... there is a lack of chassis builders in the G7 aftermarket countries for a reason ... they have to be certified by engineers, crash tested extensively and marketed to be lawyer proof. If your chassis fails for any reason your going to be sued beyond belief. The liability concerns make chassis building a Very Poor Business. What remains of the kit car industry pretty much only provides fiberglass bodies with fewer and fewer providing turnkey cars due to being shut down or sued constantly. If you have the capital to startup in this industry take your money and buy the real deal with money left over. IMHO

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          • #6
            ooops .. deleted comments .. having a grumpy day !!!
            Last edited by CARBUILDER; 04-08-2014, 09:18 AM.

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            • #7
              "But who is to say that the builder would not get recognized by an auto manufacturer or race team and get offered something like a Project Manager position?"

              Is the the polyanna world today's universities have created? Are today's grads really this naive?
              Last edited by aflo; 04-08-2014, 09:27 PM.

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              • #8
                I own a business where we do R&D and prototyping for the automotive industry. we are currently doing a technical scope of work and a feasibility study for a small manufacture interested in building specialties limited-run vehicles. I'm also prototyping one of my own designs for a carbon monocoque chassis that we will be using in a very exclusive very small number production vehicle. here's a quick break down of just some large item and preliminary cost.
                600 hours of engineering work, design work and analysis time at a rate of $165 per hour.
                Our lower monocoque consumes 35 yards of carbon fiber in the first lay up schedule before structural cores!
                we have a 1000 cubic foot post curing oven that cycles are structural carbon fiber at a curing rate of 380 degrees Fahrenheit over a 8 hour. With a ramp up for the first three hours and then a two hour hold and a ramp down for the next 3 hours.
                then you will need all sorts of materials for the molds, which have to be post cured at 410 degrees Fahrenheit so that they can be thermally stable so that your parts don't warp.....resins, epoxy, structural cores, machined inserts for subframe mounting.. Etc...
                if I had to put a rough cost on all of the above mentioned items and labor, you are looking right around $200,000.00
                Good luck with your project. ☺

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                • #9
                  Koenigsegg uses a similar tub but they use honey comb carbon. Maybe look into that?

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                  • #10
                    Im thinking of plastic forming my panels on the cheap by using caveman technology...
                    The underground oven.
                    http://i.imgur.com/qijCZ.jpg
                    Follow my designs on Facebook fan pages. http://www.facebook.com/AutoArts

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                    • #11
                      Originally posted by brada View Post
                      I own a business where we do R&D and prototyping for the automotive industry. we are currently doing a technical scope of work and a feasibility study for a small manufacture interested in building specialties limited-run vehicles. I'm also prototyping one of my own designs for a carbon monocoque chassis that we will be using in a very exclusive very small number production vehicle. here's a quick break down of just some large item and preliminary cost.
                      600 hours of engineering work, design work and analysis time at a rate of $165 per hour.
                      Our lower monocoque consumes 35 yards of carbon fiber in the first lay up schedule before structural cores!
                      we have a 1000 cubic foot post curing oven that cycles are structural carbon fiber at a curing rate of 380 degrees Fahrenheit over a 8 hour. With a ramp up for the first three hours and then a two hour hold and a ramp down for the next 3 hours.
                      then you will need all sorts of materials for the molds, which have to be post cured at 410 degrees Fahrenheit so that they can be thermally stable so that your parts don't warp.....resins, epoxy, structural cores, machined inserts for subframe mounting.. Etc...
                      if I had to put a rough cost on all of the above mentioned items and labor, you are looking right around $200,000.00
                      Good luck with your project. ☺
                      Perhaps a case study of Mosler Auto and their MT900 would be worthwhile as they have been there done that and more....

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                      • #12
                        carbon fiber monocoques are easy to design.

                        here you go i designed this in 5 minutes, feel free to use it

                        Last edited by ncrazyballa; 04-09-2014, 09:51 AM.

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                        • #13
                          it would be cost effective to build a tube chassis cabin with larger steel side and middle supports then put a fiberglass or carbon fiber open lay up inside the cabin ,which ends up being a tube chassis with a fiberglass/carbon fiber tub inside. other options could include detachable front and rear structures that bolt to the cabin with attachment plates front and rear ,this could be done with a used engine and trans axle for under or around $30 thousand
                          In the USA if you pay a company / person to start a plug, then it,s your plug and work ,it is not theirs to sell or trade !!

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                          • #14
                            lol... thats a good one..

                            Originally posted by ncrazyballa View Post
                            carbon fiber monocoques are easy to design.

                            here you go i designed this in 5 minutes, feel free to use it

                            Comment


                            • #15
                              appels and oranges mate...
                              Originally posted by ITALIANKNIGHTRIDER View Post
                              it would be cost effective to build a tube chassis cabin with larger steel side and middle supports then put a fiberglass or carbon fiber open lay up inside the cabin ,which ends up being a tube chassis with a fiberglass/carbon fiber tub inside. other options could include detachable front and rear structures that bolt to the cabin with attachment plates front and rear ,this could be done with a used engine and trans axle for under or around $30 thousand

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