Custom Roll Cages & Safety Structures for Motorsport Applications
Engineering-driven fabrication of FIA- and SCCA-compliant roll cages and safety structures. Tube bending holds ±0.5-1.0 mm; welded assemblies hold ±1.0-2.0 mm (confirmed at quote based on fixture complexity). Materials: DOM steel, chromoly (4130), mild steel. From 7-10 business days for prototypes; production runs 2-4 weeks.
STEP · PDF · Sketch — Engineering Review & Quote
Custom Design & Engineering Support
Engineering Services
We collaborate with race builders, OEM engineers, and motorsport teams to transform safety concepts into production-ready structures. Our engineering review identifies geometric conflicts, material optimization opportunities, and manufacturing constraints early in the design phase.
Regulation Compliance Review
FIA and SCCA specification verification for materials, dimensions, and structural requirements.
3D CAD Evaluation
Geometric alignment validation and interference checking for vehicle-specific fitment.
FEA Simulation
Structural analysis for load distribution and failure mode prediction.
Engineering Review Process
- Design Upload: Submit STEP, PDF, or sketches with vehicle platform and regulation class
- Feasibility Analysis: 48-hour engineering review identifying manufacturing risks and regulation compliance gaps
- DFM Recommendations: Detailed feedback on tube routing, weld access, fixture requirements, and cost optimization
- Quote & Timeline: Firm pricing with material certificates, inspection documentation, and delivery schedule
Precision Fabrication & Welding Expertise
Our integrated process combines CNC mandrel tube bending, laser tube cutting, and fixture-controlled TIG/MIG welding to deliver dimensionally accurate safety structures with repeatable quality.
CNC Mandrel Tube Bending
Programmable bending with CLR 1.0-1.5× OD maintains wall thickness uniformity and prevents collapse. Multi-axis control ensures precise angle sequencing for complex cage geometries.
Laser Tube Cutting
Precision cutting with weld-ready copes, miters, and mounting holes in one setup eliminates secondary operations and ensures perfect joint preparation.
Fixture-Controlled Welding
Dedicated jigs replicate vehicle geometry and maintain dimensional accuracy during assembly. TIG/MIG processes follow WPS/PQR procedures for certified weld quality.
Materials & Finishing Options
Material selection balances regulation compliance, weight targets, and fabrication feasibility. We provide full material traceability with mill certificates and test reports.
Steel Options
- DOM Steel (1020/1026):Seamless cold-drawn tube; cost-effective for club racing
- Chromoly (4130):Higher strength-to-weight ratio; required for FIA homologation
- Mild Steel (ERW):Entry-level applications; adequate for recreational and some SCCA classes
Material grade confirmed per regulation class and customer specification at quote.
Surface Finishing
- As-Welded: Mill scale removed; passivation for corrosion protection
- Powder Coating: RAL colors; 60-80 µm thickness; UV-resistant for outdoor storage
- Zinc Plating: Corrosion barrier for steel components; optional clear chromate topcoat
- Paint Prep: Sandblast + primer for customer final coating
Finish selection depends on regulation requirements and environmental exposure.
Quality Assurance & Certification
All safety structures are manufactured under ISO 9001 quality systems with traceable inspection records. We provide complete documentation packages for tech inspection and homologation.
ISO 9001 Certified
Documented quality management system with controlled weld procedures, operator qualifications, and inspection protocols.
Inspection Documentation
FAI reports, in-process inspection logs, weld inspection records, and material certificates provided with every project.
Testing Services
NDT services (dye penetrant, ultrasonic) available as specified. Coordinate with third-party labs for destructive testing if required.
Documentation Package
- Material certificates (mill test reports)
- Weld procedure specifications (WPS)
- Operator qualification records
- Dimensional inspection reports
- Certificate of conformance (CoC)
Additional documentation (CoA, PPAP, third-party certification) available on request.
Motorsport & Off-Road Applications
From competition-grade roll cages to off-road protection systems, our fabrication capabilities support diverse safety structure requirements across motorsport disciplines.
Competition Roll Cages
FIA- and SCCA-compliant multi-point cages for circuit racing, time attack, and rally applications. Custom geometry for driver seating position and harness mounting.
Off-Road Protection Systems
Heavy-duty external cages and intrusion bars for rock crawling, desert racing, and utility vehicle applications. Designed for impact resistance and equipment mounting.
Prototype & Custom Builds
One-off safety structures for kit cars, custom builds, and engineering validation. Full design support from concept sketches to tech-inspected final product.
Why Partner with X-KPR
When safety structures need to move from design to competition-ready systems, X-KPR brings engineering rigor, integrated fabrication capabilities, and proven quality systems to motorsport applications.
Engineering-First Approach
48-hour DFM review identifies regulation compliance gaps, manufacturing constraints, and weight optimization opportunities before fabrication begins. Our team speaks the language of motorsport engineering.
Certified Quality Systems
ISO 9001 processes with traceable FAI → in-process → final inspections. Every weld, every bend, every dimension documented with material certificates and inspection records ready for tech inspection.
Integrated Fabrication
Tube bending → laser cutting → fixture welding → finishing in one facility eliminates handoffs and coordination complexity. Single point of contact from engineering review to final delivery.
Frequently Asked Questions
Can you fabricate roll cages to FIA specifications?
What tolerances do you hold for cage fabrication?
Do you provide design engineering support?
What materials do you work with for safety structures?
Request a Quote — Upload Your Design
Tell us your vehicle platform, regulation class, material preferences, and project timeline. We'll return DFM feedback and a firm quote within 48 hours.
Accepted Formats: STEP · PDF · Sketches · Photos · DWG
Related Services
RFQ Form
This section will be replaced by an Elementor Form widget in production.
Form fields: File Upload, Vehicle Platform & Regulation Class, Material Preference, Quantity, Surface Finish, Required Documentation, Target Delivery Date, Additional Notes