Purpose
The Structures Subsystem is responsible for the core structural elements of the race car, ensuring strength, stiffness, safety and integration with all other vehicle systems. This team oversees both the traditional chassis framework and a number of additional structural housings and support assemblies. Collaboration with other subteams is essential to define design constraints, meet competition regulations, and optimise vehicle performance.
Goals
| Primary Goals |
|---|
| Design and manufacture structural components. |
| Integrate key components |
| Ensure compliance with FSAE-A regulations and safety standards |
| Secondary Goals |
|---|
| Weight optimisation |
| Research into alternative chassis designs |
Key Components
Space Frame
The Space Frame is the most significant component of the chassis. It is a structural assembly that supports all functional vehicle systems. The chassis comprises two different systems: a space frame and a monocoque. At MUR, we use a Space Frame as it is much quicker and cheaper to manufacture and, as a result, is easier to modify should changes be required. We design the space frame according to the FSAE-A rule book and the Structural Equivalency Spreadsheet (SES), which guides how the chassis needs to be built to make it a safe and rules-compliant chassis. These designs are created using Fusion 360, where we also run FEA to ensure the chassis is structurally sound and can protect the driver in the case of a crash.
Tractive Battery Housing
A structural enclosure that protects the high voltage battery system (Tractive Battery). The housing is designed to meet safety, mounting and integration requirements for the tractive system. The team is also responsible for the mounting of this battery into the car. Along with the transport and design of the charger housing.
Electrical Housing
These enclosures protects low voltage electrical components including the ECU (Electrical Control Unit), PDM (Power Distribution Module) and MSS (Main Safety Shutdown). It must provide mechanical protection, thermal management and compliance with safety protocols.
Impact Attenuator
The Impact Attenuator, or IA, lives at the front of the car. It is also known as a crash cushion. It is designed to reduce damage to the vehicle in the event of a collision. It is a prefabricated component built with a honeycomb pattern to maximise its effect in reducing the damage in a crash. It works similarly to a crumple zone in a road car.
Floor
The Floor of the car prevents any track debris from entering the car. As expected, the vehicle's floor is at the bottom of the car and extends to all sections in the driver compartment. The floor is made from a solid and robust material that will hold the weight of the driver and protect the driver from any debris entering the vehicle.
Firewall
The firewall protects the driver by providing a barrier between the driver and the electrical and cooling systems. In the case of a fault, fire or impact, the firewall acts as a thermal, electrical and physical barrier.
Future Research Projects
Geometry optimisation can minimise the chassis' mass and improve packaging to create a smaller and lighter car. This allows for improved handling and acceleration. Improvements to the design can work to increase rigidity and reduce torsional twisting. Further research can be conducted into monocoques of carbon or other materials for implementation in future years, allowing for a much broader approach to engineering a race car.
Industry and Work Opportunities
Working on the Chassis subsystem in MUR Motorsports offers a range of industry and career opportunities. The technical skills gained in chassis design, structural engineering, and CAD modeling are directly applicable to automotive and aerospace engineering, where engineers focus on vehicle and aircraft structures.
In motorsports, these skills are essential for designing race car frames that balance safety and performance. Hands-on experience with CNC machining, welding, and assembly also prepares team members for roles in manufacturing, where practical knowledge of production processes is highly valued.
Additionally, the principles of structural integrity and impact attenuation developed in the Chassis team are useful for careers in mechanical and structural engineering. These skills make graduates well-suited for a variety of engineering roles, including chassis design, manufacturing, and project management.
Materials and Manufacturing Exposure
| Materials |
|---|
| Chrome-moly Steel |
| Mild Steel |
| Aluminium |
| Carbon Fibre |
| Plastics (ABS, PETG, PC FR) |
| Manufacturing |
|---|
| Laser Cutting |
| CNC Machining |
| Milling |
| Lathing |
| Welding |
| Composites Layups |
| Composites Resin Infusion |
| 3D Printing |