Second newsletter: Chassis and Vehicle Dynamics lead ER26's engineering

Second Newsletter for the ER26 project

Welcome to the second edition of the ER26 newsletter! In this letter we cover the engineering teams Chassis and Vehicle Dynamics—two teams that are vital for the car’s main structure and functionality. Continue reading to learn their core responsibilities and how they collaborate to keep the project on track.

Chassis – The Backbone of the Car

Every Formula Student car needs a strong and well-engineered skeleton to function. It’s the structure that holds the entire car together physically. This project, our Chassis Team is exploring new design solutions to decrease weight and start implementing carbon fiber instead of relying only on steel tubes like previous years.

The Chassis Team consists of ten dedicated members, divided into two main groups: the frame and the driver’s environment. In addition, one member focuses on composite development and another on structural calculations. Together, the team is responsible for designing and manufacturing the car’s chassis—a process that needs to be finished early in the car’s development since other teams depend on it.

Their work covers everything from the load-bearing steel space frame to the driver’s environment, which includes the seat, headrest, steering wheel, and related safety systems. Because the chassis endures significant forces during racing, each component must undergo thorough verification. This involves extensive manual calculations and simulation analyses, ensuring every part achieves the perfect balance between low weight and maximum strength.

Material selection is critical for both performance and safety. The frame is primarily made from steel tubes, complemented by steel and aluminum sheet components. Within the driver’s environment, several parts are made from carbon fiber composites. Safety systems, which must comply with Formula Student regulations, are sourced externally.

Thanks to strong partnerships with our sponsors, the chassis tubes we get from ME Racing are laser-cut by Luni and bent by BS Rörbock before being TIG-welded together in the university’s workshop. Most other parts are also produced in-house, from water-cut and bent sheet metal to MDF molds for carbon fiber manufacturing. All composite production takes place in LiU’s composite lab, handled directly by the team.

Time management is a critical aspect for the Chassis Team. As one of the first components that must be completed, the chassis sets the pace for the entire production phase. The goal is to finalize all frame design work—including the welding jig—by early December, followed by the rest of the chassis design in mid-December.

The biggest innovation this year is the introduction of carbon fiber panels replacing certain steel tubes. This marks an important step in the team’s long-term vision of transitioning to a monocoque chassis, where the chassis and bodywork form a single integrated structure. While this shift introduces new challenges in testing and validation, it also promises progress in weight reduction and structural stiffness.

Vehicle Dynamics – Bringing the Car to Life

The Vehicle Dynamics Team is responsible for all the moving components of the car—the systems that allow it to accelerate, brake, and steer. They define the car’s dynamic behavior through simulations and iterative design work, ensuring that it’s drivable.

The team consists of 17 engineers working on complex mechanical systems such as suspension, steering, drivetrain, and brakes. Some members focus more on simulations and analysis, studying how tire and suspension parameters affect overall vehicle performance to refine the car’s behavior.

For the ER26 project, the goal is to build a car with improved reliability and performance through data-driven design. One of the team’s most important milestones is determining the suspension pickup points, which have a major impact on the entire vehicle’s dynamics. During spring, the team also leads the Rolling Chassis milestones—the exciting moment when all systems are installed and the car rolls and steers for the first time.

Collaboration is essential for the Vehicle Dynamics Team. Almost every system they develop interacts with other teams, requiring clear communication and teamwork. For instance, the suspension system directly affects the Chassis Team, while the drivetrain requires close coordination with the Packaging Team.

A major focus this year for the team is improving how simulation tools, physical testing, and validation are used together. By analyzing real data from tests and simulations, the team aims to make more informed, data-driven engineering decisions that enhance the car’s reliability and performance.

Together, the Chassis and Vehicle Dynamics teams form the foundation of our Formula Student car by combining engineering precision, teamwork, and new solutions to improve the reliability and performance of the car.

LiU Formula Student – where students become professionals.