As we have started production of this years car, we thought it would be interesting to show you how our monocoque is made. Here you can read about parts of the process of making a car in carbon fibre. We have been fortunate to have being sponsored by Eker Design and by High Performance Composites (HPC), both located in the Fredrikstad area.

We have used negative moulds to make our car. They were made by Eker Design and CNC-milled from our CAD-model. The process starts with milling the shape of our car slightly to big into our blocks. These moulds are then covered by an epoxy paste. When the paste has hardened, there is a new round of milling. This is the fine milling where the moulds get the exact dimensions. We would like to thank Eker Design for their help.

Initial milling

Milling the epoxy paste

When the moulds had been milled, they were transported to HPC and coated. Four team members and one apprentice from NTNU travelled to HPC’s facility to make the car parts in carbon fibre. Here we were guided by Paal, the owner of HPC, through the process. We would like to thank HPC for helping us with their expertise and equipment! We here at DNV GL Fuel Fighter are very grateful that they have decided to sponsor us! With their help we are sure we will do even better in London this May!

Consulting with Paal, and layup of carbon fibre.

Vacuum infusion

We now have the parts back in Trondheim. There is yet some work to do with grinding, cutting excess carbon fibre and assembly of the pieces. We will now finish the monocoque, in parallel to producing other parts, in the time to come. It is an exciting time for us and we look forward to revealing our car to you.