Developing a composite racecar monocoque

Abstract

The purpose of this study was to develop a suitable vehicle body for the Metropolia University of Applied Science's electric vehicle, E-RA, by using modern materials and manufacturing technologies.

This study incorporates the whole vehicle design process, from the idea to the realisation of the prototype. The focus is on the vehicle body. First, a set of boundaries is established in order to create a vehicle body concept which is then developed into a self-supporting carbon monocoque by using various engineering methods. Subsequently, the modelling, the simulation, the manufacturing technology and the mould technology are chosen, and the material models are created. The chosen manufacturing- and mould-technologies are examined in depth.

The finished body is systemically examined at each stage of development. Based on these development points a development plan is created in order to produce a small series suitable vehicle body concept.

This study resulted in the development of a self-supporting carbon prepreg vehicle body that functions as the platform for the E-RA electric vehicle. In the development of this vehicle, the team was able to draw on a number of key elements, namely the 20 years of experience by Metropolia in making one-off vehicles, modern engineering tools and materials and the possibility to use future technology.

This study resulted in creating a new type of applied manufacturing method for building similar structures more efficiently