FR-1 Composite Chassis Development ( VCAMM / AutoHorizon/ Boeing Areostructures Australia/ Marrand Precsion Engineering) Chassis Designer & Builder Russell Gallagher
The Fr-1 story began with the development of its unique carbon fibre chassis. Our Chassis was a feasibility trial that led to the design and construction of Australia’s first light-weight passenger vehicle structure, made from low curing composite materials.
This structure forms the primary structure of the FR-1 concept car. This manufacturing milestone, when designed and constructed, was of great significance. It is the first Australian-designed-and-built passenger vehicle structure to be made from composite materials.
It has been produced using a new, locally developed, low-temperature-curing carbon fibre material. By design, this particular technology was regarded as a breakthrough in providing a low-cost and commercially sustainable alternative to traditional carbon fibre-based manufacturing.
Manufacturing with conventional carbon fibre-based material technology is very expensive, even though it’s widely regarded as best practice and technology-leading, it also has a high energy and emissions footprint. It’s also widely regarded as too expensive to be considered commercially viable for the general mass production of passenger vehicles.
This successful primary structure which was developed and made at the Auto Horizon Foundation studio Automotive Centre of Excellence (ACE) Docklands, in conjunction with our program partners, demonstrates Australia’s capacity for advanced manufacturing. This program also showcases local abilities in developing sustainable, efficient, and safe automotive technologies.
In addition, this successful studio trial demonstrated leadership in working with industry, technology transfer entities and government, to help achieve the objective of developing light-weight structures, as was outlined by the Automotive Australia 2020 Technology Roadmap.
The following outcomes were achieved from the FR-1 carbon structure, design and construction process;
The cured substructure program allowed AHF & VCAMM team to learn how to best develop protocols for layup carbon fabric into complex and taxing 3D shapes, not commonly created or practised in the automotive or current aerospace industry.
The technical team created new tools for embossing carbon material into sharp and compound radii.
The FR-1 composite program provided an opportunity to develop and assess how our low-cost fibreglass vacuum mold tools.
The carbon lay-up program taught the technical team how to improve vacuum bag techniques, test and diagnose critical leaks succinctly and effectively.
Technology diffusion; the following companies had supported or engaged in our carbon lay-up trials; Boeing Aerostructures, Marrand, Holden Design, Toyota Design and Belmont Nominees.
Our first trial highlighted and will inform future design criteria profoundly based on our current studio trials.
Our work with light weight composites, as applied to both outlined programs, is one of the few field studies undertaken in Australia. The build team owe a great debt of gratitude to Boeing Aerostructures Australia; Boeing provided insight, direction and valuable- practical knowledge, and mentoring throughout the application and lay-up phase.
Our first trial highlighted and will inform future design criteria profoundly based on our current studio trials.
Our work with light weight composites, as applied to both outlined programs, is one of the few field studies undertaken in Australia. The build team owe a great debt of gratitude to Boeing Arostructures Australia; Boeing provided insight, direction and valuable- practical knowledge, and mentoring throughout the application and lay up phase.
FR-1 Project Introduction: BTW Corporate & Social Responsibility Program
FR-1 Project Ep1: Concept Design Presentation – Created by GM-Holden Design (Robert Walker)
