Electric 'HIPERCAR' roll cage

Aims

We were challenged to manufacture a new, lightweight roll cage for the electric HIPERCAR, to replace the existing roll cage made from steel. The new structure had to be as strong as the steel one, perform just as well in load tests, and have a similar failure mode.

Outcomes

We created a new thermoplastic-based composite roll cage, which was:

  • Over 52% lighter than the existing steel structure
  • Just as stiff and strong
  • Superior in NVH (noise, vibration and harshness) performance
  • Proven to have a similar failure mode to steel.

For this project, we replicated the geometry of the steel structure with composites (a ‘black metal approach’), so we could prove that performance improvements were caused by the material change.

If we redesigned the structure specifically for composite manufacturing, we could make further improvements in strength, stiffness and weight.

Outcomes

We created a new thermoplastic-based composite roll cage, which was:

  • Over 52% lighter than the existing steel structure
  • Just as stiff and strong
  • Superior in NVH (noise, vibration and harshness) performance
  • Proven to have a similar failure mode to steel.

For this project, we replicated the geometry of the steel structure with composites (a ‘black metal approach’), so we could prove that performance improvements were caused by the material change.

If we redesigned the structure specifically for composite manufacturing, we could make further improvements in strength, stiffness and weight.

"It was great to work with the whole team at Composite Braiding, producing an exciting high performance product"
Tom Ford
Ariel Motor Company

Other applications

The roll cage was made from a series of structural tubes with varying diameters and cross-sections. These tubes can be used to produce a wide range of products for infrastructure, transportation and even sports equipment.

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Award-winning

Our technology has been recognised as world-leading. Working with a consortium of other manufacturing companies, we won two global innovation awards for the design of a very light rail carriage:

Get in Touch

Address
Composite Braiding Ltd, Dunstall Park Rd, Allenton, Derby DE24 8HJ, UK