Design, development, and manufacture of an aluminium honeycomb sandwich panel monocoque chassis for Formula Student competition

H. C. Davies, M. Bryant, M. Hope, C. Meiller

Research output: Contribution to journalArticle

3 Citations (Scopus)


Cardiff University students have used the freedom of the Formula Student rules to create an innovative chassis that combines a high performance with an efficient manufacturing process. All aluminium sandwich panels were pre-cut using computer numerical control routing, which is a rapid low-cost operation that produced highly accurate results. Assembling the monocoque consisted of folding and bonding panels along pre-routed lines and reinforcing the relevant joints. This required no specialist tools or equipment and was a rapid non-labour-intensive operation. The key design features, the manufacturing techniques, and the results of experimental and computational performance testing are presented here. This chassis construction technique is the result of research and development for seven years over six generations of Formula Student race cars.

Original languageEnglish
Pages (from-to)325-337
Number of pages13
JournalProceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering
Issue number3
Publication statusPublished - Mar 2012



  • aluminium honeycomb
  • Formula SAE
  • Formula Student
  • monocoque chassis
  • race car safety

ASJC Scopus subject areas

  • Mechanical Engineering
  • Aerospace Engineering

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