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BODYWORK

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​INNOVATIVE LIGHTWEIGHT CHASSIS

​Multi-material support structures for maximum strength with minimum weight

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WEIGHT & COST OPTIMIZED

Body development for all types of vehicles

Our strength in the development of lightweight systems and components is fully reflected in the development of all types of body structures:

  • Spaceframe/Tube frames

  • Monocoques

Made from high-strength steels, aluminum, magnesium, plastics, and especially composite materials such as carbon fiber (CFRP), fiberglass (GFRP), and more.

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​Concept & design

​Holistic expertise in system conception

In chassis development, we consider factors such as safety, performance, handling, comfort, and cost. Essential for the development of self-supporting and skeletal bodies are:

  • Requirements analysis: Defining the vehicle class, usage, weight, number of passengers, and more.

  • Definition of construction goals: Goals such as weight optimization, strength, rigidity, and crashworthiness.

  • Material selection: Planning based on function, joining techniques, corrosion protection, and quality requirements.

  • Structural analysis and design: CAD modeling and finite element analysis of various chassis designs.

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Design in CAD

Manufacturing-optimized modeling of components

We develop chassis and underbody assemblies and integrate them into the complete vehicle with all relevant interfaces. The following design areas are specifically offered for composite assemblies:

  • Component design and manufacturing-oriented optimization

  • Model and mold design

  • Fixtures for finishing and component assembly

  • Optimization for CNC machining

  • Design of laminate structure

  • CAD-based cutting plan creation

  • Creation of manufacturing documentation

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​(CRASH) SIMULATION

​FIA certified for calculation of safety structures

As one of only a few companies worldwide certified by the World Motorsport Authority FIA to calculate safety structures, we verify critical component functions through Finite-Elemente-Analysis (FEA).

Insights gained from FEA calculations immediately contribute to optimization during the development process:

  • Geometry preparation for FEA model creation

  • Calculation of complex structures

  • Load cases

  • Non-linear analysis

  • Determination of strength/stiffness

  • Topology optimization and shape optimization

  • Fatigue strength verification

  • Calculation of composite fiber structures

  • Calculation and analysis of composite/plastic materials

  • Crash simulation

  • Transient mechanics

  • Modal analysis​​

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Production

​Multi-material systems for prototypes and series

Gerne nutzen wir unser umfangreiches Lieferanten-Netzwerk und übernehmen bzw. unterstützen Sie bei der Auswahl eines geeigneten Fertigungsverfahrens, wie z.B.:

 

  • Pressen (Tiefziehen und Stanzen)

  • Schweißen

  • Spritzguss

  • Hydroforming

  • Aluminiumguss

  • additive Fertigung (3D-Druck),

  • CNC-Fräsen

  • Laserschneiden

  • Autoklav-Verfahren (Faserverbund)

sowie Finishing-Verfahren, wie Schleifen und Beschichten (Lackieren, Galvanisieren uvm.)


Bei Bedarf übernehmen wir gerne auch die abschließende Qualitätssicherung:

  • Soll-Ist-Vergleich

  • Technische Dokumentation

  • Hardware-Tests

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PROTOTYPING

Assembly of complete body structures

We organize, schedule, and document the assembly of chassis complete systems in our in-house prototype workshop, or manage small series production and take care of quality control.

In this way, a complete vehicle body is created from individual components.

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References

​Vehicles with our bodywork developments on board.

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References

​Vehicles with our chassis developments on board.

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References

​Vehicles with our chassis developments on board.

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References

​Vehicles with our chassis developments on board.

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References

​Vehicles with our chassis developments on board.

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References

​Vehicles with our chassis developments on board.

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