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From CAD to Chassis Fixturing

Chassis Development

Designed as a Complete Vehicle System

A high-performance chassis is more than a frame with suspension attached to it. Suspension geometry, steering, brakes, drivetrain placement, ride height, wheel and tire packaging, chassis structure, component clearances, and serviceability all affect one another.

ACD develops these systems together from the beginning. The vehicle establishes the physical envelope and intended use, and the chassis is developed around those requirements.

This approach allows decisions about suspension geometry and chassis structure to be made with an understanding of how they affect the complete vehicle. The objective is a chassis that delivers excellent ride quality, responsive handling, precise steering, strong braking, stability, and predictable real-world behavior.

Every component has a job. Every mounting point has a reason..

Our Method

Engineered for Performance

CAD Modeling

Digital Development

Geometry and Packaging Before Fabrication

Development begins in CAD, where the vehicle envelope, suspension, steering, drivetrain, wheels, tires, brakes, and chassis structure can be evaluated together before physical components are fabricated.

Suspension pickup points are established around the requirements of the vehicle rather than predetermined frame dimensions. Control-arm lengths and angles, camber behavior, roll-center location and movement, caster, steering geometry, suspension travel, and coilover motion ratios can all be evaluated as the suspension moves through its operating range.

Steering is developed as part of the front suspension. Rack position, steering-arm geometry, tie-rod relationships, Ackermann, bump steer, tire clearance, and steering range must work together rather than being addressed after the suspension has already been established.

Packaging is developed at the same time. Engine and transmission placement, differential location, axle geometry, exhaust clearance, wheel and tire dimensions, body clearance, ground clearance, and service access can influence both suspension and chassis design.

This process allows conflicts to be identified digitally, where changes can be evaluated efficiently, instead of discovering them after a chassis has already been fabricated.

The goal is not simply to make everything fit. The goal is to make everything work together.

Physical Development

Precision Fixturing

FROM CAD TO STEEL

Designed for Accurate, Repeatable Fabrication

Once the suspension geometry, vehicle packaging, and chassis structure have been developed, the digital design must be translated accurately into a physical chassis.

ACD uses fabricated frame rails and crossmembers designed around the requirements of the vehicle. Chassis components can be CNC-cut from the CAD design so that profiles, slots, holes, mounting features, and component locations are established directly from the digital model.

Purpose-built chassis fixtures then establish critical locations in three dimensions during fabrication. Frame rails, crossmembers, suspension pickup points, body mounting locations, and other critical components can be located relative to known reference points rather than relying solely on manual measurements during assembly.

Fixture design is part of the production-development process. A prototype needs to establish more than whether a chassis can be built once—it must help determine how the same critical geometry can be reproduced accurately when additional chassis are manufactured.

Practical fabrication is considered throughout the design process. Component access, weld sequencing, assembly, serviceability, material usage, and the ability to manufacture the chassis consistently all influence how the final structure is developed.

The digital model establishes the design. The fixtures make it repeatable.

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Shape Future Platforms

Prototype To Production

Build. Test. Refine.

CAD can establish geometry, analyze relationships, and identify packaging conflicts, but the development process does not end when the design leaves the computer.

A physical prototype allows the complete chassis to be assembled with the suspension, steering, brakes, drivetrain, wheels, tires, and vehicle body. Clearances, suspension travel, steering range, component access, serviceability, and vehicle packaging can then be evaluated with the actual components working together.

Once the prototype vehicle is operational, physical testing provides the opportunity to evaluate the characteristics that ultimately matter to the driver. Ride quality, steering response, handling balance, braking behavior, suspension control, stability, and real-world drivability can be evaluated as a complete vehicle.

Testing also provides an opportunity to identify areas where the digital design or physical chassis can be improved. Those findings can be incorporated back into the CAD model, fabrication process, or component specifications before the design is finalized.

Only after that process is complete does a development chassis become a production design.

CAD DEVELOPMENT

Develop the suspension geometry, steering, vehicle packaging, and chassis structure as an integrated system.

PROTOTYPE FABRICATION

Translate the digital design into CNC-cut components and purpose-built fabrication fixtures.

VEHICLE INTEGRATION

Assemble the complete chassis and verify suspension travel, steering, clearances, component packaging, and serviceability with the actual vehicle.

PHYSICAL TESTING

Evaluate ride, handling, steering, braking, stability, and overall vehicle behavior under real-world conditions.

REFINEMENT

Use what is learned during fabrication, assembly, and testing to improve the design before production.

PRODUCTION

Finalize the chassis design and fabrication process around repeatability, quality, serviceability, and consistent suspension geometry.

Design it. Build it. Test it. Refine it. Then put it into production.