Custom Chassis & Subframes — Engineered for Performance, Precision, and Reliability

Engineering-driven fabrication of space-frame chassis, tubular subframes, and modular platforms for motorsport, EV prototypes, and kit cars. Tube bending holds ±0.5-1.0 mm; welded assemblies hold ±1.0-2.0 mm (confirmed at quote based on geometry). Materials: chromoly (4130), aluminum alloys, DOM tubing. From 10-15 business days for prototypes; small-batch production 3-5 weeks.

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Custom Chassis Design & Engineering

Engineering Services

We collaborate with motorsport teams, OEM engineers, and EV startups to develop space-frame chassis, modular subframes, and lightweight platforms. Our design process balances stiffness targets, weight constraints, and assembly complexity through iterative analysis and prototype validation.

FEA Structural Analysis

Load path optimization, stress concentration identification, and torsional rigidity validation.

Suspension Geometry Verification

Pickup point alignment, roll center analysis, and kinematic conflict checking.

Material Selection Guidance

Chromoly vs aluminum tradeoffs, tube sizing optimization, and weight-to-stiffness analysis.

Design-to-Fabrication Process

Concept Review: Submit CAD files, performance requirements, and weight targets
FEA & DFM Analysis: 48-hour engineering review with structural validation
Prototype Fabrication: Build first article with dimensional verification
Validation & Iteration: Physical testing and geometry adjustments

Advanced Fabrication & Assembly

Integrated tube bending, laser cutting, and precision welding capabilities deliver dimensionally consistent chassis structures with repeatable quality across prototype and low-volume production runs.

CNC Tube Bending

Multi-axis mandrel bending maintains wall thickness uniformity and prevents tube collapse during complex angle sequences. Programmable bend sequences ensure identical geometry across production batches.

Laser Cutting & Gussets

Precision sheet cutting for gusset plates, mounting tabs, and reinforcement brackets. Laser-cut profiles enable tight-tolerance fitment and reduce secondary machining operations.

Modular Jig Assembly

Dedicated welding fixtures replicate mounting geometry and maintain dimensional accuracy during TIG/MIG assembly. Fixture-controlled processes ensure identical pickup point locations across chassis builds.

Materials & Structural Optimization

Material selection balances strength, weight, weldability, and cost constraints. We provide engineering guidance on tube sizing, alloy selection, and hybrid material strategies for optimized chassis performance.

Structural Tube Materials

Chromoly (4130): High strength-to-weight ratio; ideal for motorsport applications
Aluminum Alloys (6061-T6, 7075): Lightweight; excellent for EV chassis
DOM Steel (1020/1026): Seamless cold-drawn; cost-effective for kit cars
Stainless Steel (304, 316): Corrosion resistance for outdoor storage

Gussets & Reinforcement

Laser-Cut Steel Gussets: 3-6mm thickness with precise hole patterns
Formed Brackets: CNC-bent mounting tabs with controlled bend radii
Machined Inserts: Threaded bungs, bearing housings, precision mounting points

EV & Lightweight Applications

Electric vehicle chassis require battery integration, motor mounting, and optimized weight distribution. We support EV startups and research programs with rapid prototyping and small-batch production capabilities.

Skateboard Chassis Platforms

Aluminum or steel space-frame structures with integrated battery tray mounting and structural floor reinforcement.

Motor & Drivetrain Mounts

Precision welded subframes with machined motor mounts, gearbox interfaces, and axle pickup points.

Weight Optimization

FEA-driven tube sizing and material selection to minimize chassis mass while maintaining torsional rigidity targets.

Motorsport & Kit Car Expertise

From Formula SAE chassis to replica kit car frames, our fabrication capabilities support diverse performance vehicle applications with engineering precision and manufacturing consistency.

Formula & Prototype Racing

Custom space-frame chassis for Formula SAE, FSAE Electric, and spec-series racing. Full FEA validation, suspension geometry analysis, and regulation compliance verification included.

Replica Kit Car Chassis

Reproduction space-frame chassis for classic sports car replicas including Lotus Seven-style, Cobra, and vintage race car platforms. CAD-based design with period-correct geometry.

Electric Kart & Utility Chassis

Custom chassis for electric kart racing, industrial utility vehicles, and specialized mobility platforms. Optimized for battery pack integration and operational durability.

Why Partner with X-KPR

When chassis designs need engineering validation and manufacturing execution, X-KPR provides integrated capabilities from FEA analysis through precision fabrication to deliver production-ready structures.

Engineering-Driven Partner

48-hour DFM review with FEA validation, suspension geometry verification, and manufacturing optimization. Our team speaks the technical language of chassis design and structural analysis.

Integrated Fabrication

Tube bending → laser cutting → welding → finishing → inspection under one roof eliminates supplier coordination complexity. Single point of contact from engineering review to final delivery.

Prototype-to-Production Flexibility

Modular jig systems enable rapid changeover between different chassis designs. Ideal for low-volume production (5-50 units) with consistent dimensional accuracy and traceable quality documentation.

Frequently Asked Questions

Can you build Formula or prototype chassis?

Yes. We specialize in custom space-frame and tubular structures for Formula SAE, spec-series racing, and R&D prototypes. Our engineering team provides FEA validation, suspension geometry analysis, and DFM optimization for structural rigidity and weight targets. All chassis designs reviewed for regulation compliance (FSAE, SCCA, etc.) before fabrication begins.

What materials can you use for chassis fabrication?

We work with chromoly steel (4130), DOM tubing, aluminum alloys (6061-T6, 7075), and stainless steel depending on stiffness, weight, and application requirements. Material selection confirmed during engineering review based on FEA load analysis, weld accessibility, and cost targets. Hybrid designs (steel frame + aluminum subframes) available for weight optimization.

Do you fabricate subframes or suspension mounts?

Yes. We produce modular front and rear subframes with integrated suspension pickup points, engine mounts, and drivetrain interfaces. All mounting geometry verified with alignment fixtures and CMM inspection before delivery. Subframes can be standalone bolt-on structures or welded-in permanent installations depending on application.

Can you handle small-batch or EV prototype projects?

Absolutely. We provide rapid-turnaround engineering and fabrication for low-volume builds (1-50 units) including electric vehicle skateboard chassis, battery enclosures, and motor mounting structures. Typical prototype timeline: 2-3 weeks from engineering approval to first article delivery. Production batches scheduled based on fixture availability and finishing requirements.

Request a Quote — Upload Your Design

Tell us your performance targets, weight constraints, material preferences, and project timeline. We'll return DFM feedback with FEA insights and a firm quote within 48 hours.

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Accepted Formats: STEP · IGES · CAD · PDF · Sketches

RFQ Form

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Form fields: File Upload, Application & Performance Targets, Material Preference, Weight Target, Quantity, Required Services, Target Delivery Date, Additional Notes

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