“To geometrically design a good monocoque chassis, there are a couple of things that need to be taken into consideration. To begin with, it is important to ascertain the features of the monocoque and how to leverage them to benefit the structure Secondly, it is important to define the amount of available space for the structure in the assembly packaging. Finally, it is crucial to identify which components of the chassis are structurally signficant in terms of load paths and forces.. Before starting the process, the structure was prepared to be symmetric along the ZY plane.
This means that only half of the model had to be modeled as it was mirrored at the end of the process. Due to the fact that different modeling techniques are used, the design process was divided into the monocoque tub and roof pillars”, explains Mateusz Michalski, Chief Mechanical of ZEM. “In the end, we were able to print the car exactly as we designed and desired it. This was again proof that with additive manufacturing, you can create anything you want, even cars!”, explains Rien Becker, Exterior of ZEM. We used rPETg, made from recycled cooking oils. We were able to print with this highly sustainable material like any other plastic could do. “Not having to create molds reduced the amounts of waste greatly, adding up to our sustainability”, explains Becker.