The roll cage is a critical safety component of the off-road vehicle, designed to protect the driver in the event of a rollover or impact. Using 3d CAD software We optimize the design for strength, stiffness, and weight. We consider factors such as material selection, tubing diameter and thickness. We work with metal fabrication tools, such as tube benders and welders, to fabricate and assemble the roll cage accurately. Static load testing and dynamic impact testing are done to evaluate the roll cage's performance under different scenarios to maximize safety.

The entire rollcage of the ATV relies on the proper fabrication of the weldments. An efficient way of creating the perfect weldments is done by notching the tubes with the help of CATIA V5. The 3 dimensional CAD model is used to generate 2 dimensional intersecting profiles which are printed onto papers and then fabricated accordingly to ensure air tight weldments.