Custom Safety Structures & Roll Cages for Racing Vehicles

Engineering-grade roll cages, frame reinforcements, and protective tube assemblies for track-ready vehicles. Tolerances ±0.3–0.5 mm for mandrel bending; assembly ±0.5–1.0 mm confirmed at quote. DOM and chromoly materials. From 10–14 business days; 48h DFM & quote; FIA/SFI compliance support.

Upload Design — 48h Feasibility View Applications

Accepted Formats: STEP · IGES · DWG · SLDPRT · PDF

Custom Roll Cage & Safety Structure Design

Design-for-Manufacturing (DFM) Review

Every roll cage and safety structure begins with engineering precision and regulatory compliance. Our design and manufacturing teams work with racing teams, OEMs, and motorsports engineers to ensure each structure delivers maximum strength, optimal weight distribution, and seamless integration.

We evaluate every design for structural integrity, impact loading, and compliance with FIA, SFI, or NHRA standards. Whether you need a full-frame roll cage, custom chassis bracing, or impact protection structures, we optimize for safety, performance, and manufacturability.

Load path analysis for impact zones and mounting points
Tube sizing optimization for strength-to-weight performance
Miter and joint design for seamless welding and clean assembly
Integration points with existing chassis and suspension systems
Compliance validation for FIA, SFI, or NHRA standards

Engineering Review Process

From upload to production release, we guide your design through comprehensive technical review:

Upload Drawings — STEP, IGES, DWG, or detailed sketches with load specifications
48h DFM Feedback — Structural review, material recommendations, fabrication feasibility
Safety & Compliance Review — Regulatory alignment with FIA, SFI, or NHRA standards
Production Release — Finalized specs move to fabrication with quality documentation

Precision Tube Fabrication & Welding for Safety Structures

Each roll cage and safety structure is built using CNC mandrel bending, laser tube cutting, and certified TIG welding under controlled processes. This ensures accurate curves, strong weld seams, and structural reliability essential for high-performance racing.

CNC Mandrel Bending

Seamless curves for roll cage hoops and reinforcement bars. Tolerances ±0.3–0.5 mm dependent on tube diameter, radius, and material springback.

TIG/MIG Welding

High-strength weld seams with visual and penetrant inspection. Assembly tolerances ±0.5–1.0 mm confirmed at quote based on joint configuration.

Laser Tube Cutting

Precision end cuts, mounting holes, and miter joints in single setup. Tolerances ±0.05–0.1 mm for feature positioning and dimensional accuracy.

Safety Standards & Regulatory Compliance

Motorsports Safety Standards

We design and fabricate roll cages and safety structures in compliance with leading motorsports regulatory bodies. Full engineering documentation supports certification and third-party testing.

FIA International Motorsport Federation regulations
SFI Specification standards for automotive safety equipment
NHRA National Hot Rod Association requirements
Load testing per motorsports engineering specifications
Material certification and traceability documentation

Welding Standards & Quality Control

Every weld on safety-critical structures is performed under controlled procedures with full traceability and inspection. Our AWS-certified welders deliver clean, high-strength seams.

AWS (American Welding Society) certification
100% visual weld inspection
Penetrant or ultrasonic testing for critical welds
Weld procedure specifications (WPS) and procedure qualification records (PQR)
Controlled heat-treat cycles for chromoly applications

Application Examples

From FIA-compliant roll cages to custom chassis reinforcements, our fabrication delivers the structural strength and engineering precision required for competitive motorsports and high-performance vehicles.

FIA-Compliant Roll Cage

Full-frame roll cage fabricated from DOM (Drawn Over Mandrel) steel tubing, welded per FIA regulations and SFI certification standards. Engineered for structural integrity and driver safety.

Custom Chassis Bracing

Reinforcement tubes integrated into existing chassis structures. CNC-bent for precise fit and TIG-welded for aesthetic finish and structural load distribution.

Impact Protection Structures

Specialized protective frames for front/rear impact zones. Designed for energy absorption and compliance with racing safety standards while minimizing vehicle weight.

Why Partner with X-KPR

When safety-critical structures need to move from concept to track-ready assemblies, X-KPR brings engineering rigor, motorsports expertise, and proven quality systems to deliver performance-grade structures on time.

Engineering-Driven Partnership

Technical expertise in racing safety standards, load analysis, and material selection. 48h DFM feedback to accelerate your design timeline and ensure compliance.

End-to-End Fabrication

Tube bending, laser cutting, TIG/MIG welding, and surface finishing all under one roof. Consistent quality control and simplified coordination from design to final assembly.

Safety & Compliance Expertise

Specialized in FIA, SFI, and NHRA safety standards. Proven track record with motorsports teams and OEM partners delivering certified, race-ready structures.

Frequently Asked Questions

What materials do you recommend for roll cages?

We use DOM (Drawn Over Mandrel) steel tubing or chromoly for strength-to-weight performance. Material selection is confirmed at quote based on load requirements, vehicle class, and regulatory specifications.

Do your structures meet FIA/SFI standards?

Yes. We design and fabricate roll cages and safety structures in compliance with FIA, SFI, and NHRA regulations. We provide engineering documentation to support certification and can coordinate third-party testing if required.

Can you integrate roll cages into existing chassis?

Yes. Our team works with existing chassis geometries, providing custom mounting points and reinforcement solutions. Engineering review ensures structural compatibility and load distribution.

What is the lead time for a complete roll cage?

Typically 10–14 business days after design confirmation. Rush turnarounds available for motorsports events; contact us for expedited scheduling.

Do you perform load or impact testing?

Yes. Load testing and structural analysis are available. We coordinate with third-party test facilities for impact and compression testing per motorsports standards.

What documentation and certifications can you provide?

We provide engineering drawings, material certifications, welding documentation (WPS/PQR), dimensional reports, and coordination support for SFI/FIA certification processes.

Request a Quote — Upload Your Drawings

Tell us your tube specifications, load requirements, regulatory standards, and timeline. We'll return DFM feedback and a firm quote within 48 hours.

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