Structural Engineering · Carbon Fiber
The Carbon
Monocoque
13pc
Interlocking Pieces
CF
Carbon Fiber
1:4
Scale Prototype
The CAT monocoque is a 13-piece interlocking structure that forms the load-bearing core of the car. Each panel is built from a PETG 3D-printed core reinforced with carbon fiber layup — combining the precision of digital fabrication with the structural performance of composite materials.
Unlike a traditional ladder or spaceframe chassis, a monocoque derives its strength from the skin itself. Every panel contributes to rigidity, distributing loads across the entire structure rather than concentrating them at discrete joints.
Designed entirely in-house, the geometry mirrors that of a full-scale supercar monocoque — same engineering principles, same structural logic, one quarter the size.
Every panel is a structural member. The interlocking geometry eliminates the need for heavy internal bracing — the shape itself does the work.
The sill panels are PETG cores wrapped in carbon fiber cloth using a wet layup process. The weave is visible on the finished surface — structural and aesthetic in one. Electronics and wiring are routed through the protected inner channels of the monocoque.
The front suspension uses a double wishbone geometry — the same architecture found in Formula 1 and production supercars — providing precise wheel control through cornering. The rear structure incorporates a dedicated crash zone, engineered to absorb impact energy exactly as it would on a full-scale vehicle.
