Helping an EV Innovator Bring a New Vehicle Platform to Life—Fast

A rapidly growing electric vehicle startup was preparing to unveil a new platform at a major industry event. They had a bold concept for a tubular chassis, but the design wasn’t fully finished, and the clock was already ticking toward their Detroit debut.

They needed a partner who could finalize the design, engineer every missing detail, fabricate the entire chassis, powder coat it, and ship it across the country—all on a schedule that left no room for delay.

They turned to APE to keep their launch on track.

The Problem: A Complex Tubular Chassis With Hundreds of Parts—and Not Enough Time

Tubular chassis systems offer excellent strength-to-weight performance for EV platforms, but they also introduce significant manufacturing complexity. The client faced several challenges at once:

• Over 200 custom sheet metal brackets needed precise location and fit
• Complex tube geometry required accurate bending, fit-up, and weld sequencing
• Critical shop drawings were incomplete or missing entirely
• Their engineering team was already overloaded with other high-priority vehicle work
• A fixed event deadline meant failure wasn’t an option

If they couldn’t finish the design and deliver a complete chassis in time, the vehicle reveal—and the momentum behind it—would fall apart.

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Why They Turned to APE

The startup didn’t need just a fabricator—they needed a guide who could turn an evolving concept into a production-ready chassis.

They chose APE because we could:

• Take ownership of the missing engineering and documentation
• Apply practical DFM principles to streamline fabrication
• Collaborate daily with their engineering team to accelerate iteration
• Deliver a mission-critical prototype under extreme time pressure
• Bring experience from aerospace, nuclear energy, and robotics—industries where precision and speed matter most

By trusting APE with the design-through-fabrication process, their internal engineers were free to stay focused on critical vehicle systems.

APE’s Plan: Engineer Clarity → Build Accuracy → Deliver on Time

To hit the client’s deadline and ensure perfect fit and function, APE followed a clear, structured plan:

1. Complete Design Documentation & DFM Review
   APE’s engineering team finalized missing shop drawings, clarified ambiguous details, and optimized parts for manufacturability.
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2. Hybrid Precision Fixture System
   Using CNC laser-cut and formed components, machined elements, and custom 3D-printed tooling, we built a modular fixture system that ensured repeatable, accurate weld prep.
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3. Seamless Vendor Collaboration
   We coordinated closely with our tube bending partner to validate dimensions, minimize lead time, and prevent downstream assembly issues.
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4. DFM-Driven Part Optimization
   Sheet metal brackets and tube interfaces were refined—split, consolidated, or re-engineered—to improve build efficiency without sacrificing performance.

Real-Time Engineering CoordinationTight feedback loops with the client kept the project aligned, prevented redesign cycles, and protected the delivery timeline.

‍The Bigger Picture

Whether it's EV chassis prototypes, aerospace assemblies, or robotic structures, APE helps innovators move from concept to validation faster. We combine DFM expertise, advanced engineering, and world-class fabrication to reduce risk and accelerate development.

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Ready to Build Your Next Breakthrough?

If you're developing advanced vehicles, high-precision mechanical systems, or any prototype where speed and accuracy matter, APE delivers end-to-end design-through-fabrication solutions for industries where failure is not an option.

Let’s build something extraordinary. Contact us to start your next project.