How Car Chassis Are Made

How Car Chassis Are Made

The chassis embodies a car showing its aerodynamic shape while hiding the ugly sub-assemblies and other components.

In the production process, the car chassis is made. The car chassis is made by combining multiple metal sections with beams using welding (spot/TIG or WIG). For softer curved sections, lighter bendable metals like aluminum are used. This is why the Tesla Truck, made of strong, hard stainless steel have sharp features.

The Chassis must be maintained well because of many properties and parts depending on chassis. Vibration and noise in large vehicles is a major issue so vehicle designers need to take all these issues into consideration. 

The purpose of chassis is to provide stability from different forces. The frame construction is of a uni-body type for most commercial and passenger vehicles. Moreover, chassis has to accommodate frame, brakes, wheels, and steering, so to maintain rigidity, modern engineering capabilities are needed to design and manufacture chassis. In this article, we will discuss how car chassis are made

Chassis Details You Should Know 

It is essential to have information about the parts of your vehicle, and then you can maintain them properly. You should understand the chassis design because it is a crucial part of the vehicle and you must have some knowledge about it.

  • What is Chassis
  • It is the basic framework of your vehicle. Sometimes it is only a frame, but most of the time it contains transmissions, wheels, and even front seats. Your vehicle will have no structure if it doesn’t include chassis. Chassis is actually a canvas on which the final construction of the vehicle is placed. Chassis are made of carbon steel, but nowadays, to produce lightweight and inexpensive vehicles, aluminum is used. 

  • Body-on-Frame Chassis
  • Two types of chassis frames are used in vehicles. One is body-on-frame, and it is the original one and used in heavier vehicles like trucks. It is called the body-on-frame because the vehicle’s body sits on the top of the frame. They don’t act as one unit, and they are separate from one another. In case of an accident, the body-on-frame is easy to repair and modify. This type of chassis made vehicles difficult to steer and handle. 

  • Unibody Chassis
  • It is clear by its name that body and chassis are one piece, and both act as the base of a car. This type of chassis is used for lighter vehicles. Such chassis made car driving and handling easy. These frames are lighter than body-on-frame; that’s why they are economical at fuel consumption. The issue with Unibody chassis is that body and frame act as one piece, so it is hard and expensive to repair them. If the damage is extensive in case of an accident, it becomes impossible to repair such chassis.

    Maintaining Your Car Chassis

    Car chassis need to be maintained. So, your car chassis must be inspected and lubricated after six months. You can perform this action by yourself, or take your vehicle to a nearby dealer or mechanic shop for maintenance. When suspension starts to creak, it is an indication that lubrication isn’t enough, and it should be immediately addressed. 

    Since chassis is the underside of your vehicle, so it needs to be frequently cleaned because it becomes caked with mud and dirt? Keeping the chassis clean can improve the driving performance and lifespan of a vehicle. You can easily perform cleaning at home with water, sponges, and oil if required. Moreover, to prevent them from rusting, paint the selected areas. 

    Chassis Design

    Chassis design should be durable, reliable, and sturdy. Engineers who design and manufacture chassis must be equipped with skills to optimize the size and weight of the chassis. For the prototype, it is better to use SolidWorks software to produce simulation. Chassis frame must be tested after designing, so check the rigidity and stability. 

    The Selection of Material for Chassis and Production Process 

    The selection of material is crucial for keeping the maintenance properties in mind. Nowadays, varieties of alloys are available with different heat treatments, properties, and manufacturing opportunities. Modern vehicles contain alloys of steel and copper. Carbon steel is used for the manufacturing of chassis, and aluminum alloys are also being used due to their lightweight characteristic. 

    Chassis contains several I, C, and U steel sections. Different operations like folding, rolling, and pressing are performed to incorporate various chassis members. Bending and press blanking are also crucial stages in chassis production. 

    The next step for the production of chassis is welding. Welding provides high strength, uniformity, and rigidity to chassis. For achieving all the characteristics, combinations of TIG and MIG are used. Finally, for preventing corrosion, wear, damage, improving the hardness, and surface treatment are performed.  Moreover, plating and coating processes are also performed. 

    Essential Things to Know about Vehicle Design

    The first and important stage of vehicle production is the design. While designing, all the elements should be taken into accounts, such as safety, aesthetic, comfort, cost, and manufacture. Designing a vehicle is a multi-stage process, so it should be flexible so that modifications can be made when a problem arises. It is important to properly identify the engine, suspension, transmission system, steering, and safety, along with the fundamental tasks.

    Noise vibrations and harshness are also important for customers. So, while designing a vehicle, along with comfort, the passengers' safety must also be taken into account. The requirements of the frame are based on loads and stability. The selection of materials is also crucial in the design of a vehicle. Nowadays, the materials used are lightweight and economical. Design engineers must take expansions and forces into account while selecting materials. 


    I hope this article will be helpful for people who don’t know much about chassis design and structure. From material selection to production process and maintenance of chassis, everything is discussed in detail. For maintaining chassis in good shape, lubricate the frame frequently. Take them to the maintenance shop every six months. Proper maintenance can enhance the lifespan of a vehicle, and also it improves the driving. 

    Efforts have been made to get the information as accurate and updated as possible. If you found any incorrect information with credible source, please send it via the contact us form
    Author: Sky Hoon
    He loved the future of self driving car and cannot wait for one. In the meantime, he loved to read up all about car and components like a computer.
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