The connected, autonomous, and sustainable mobility solutions of tomorrow will rely on intelligently engineered advanced chassis systems, writes Fabio Squadrani, Chair of FISITA’s Advanced Chassis Technology Expert Group.
As we move deeper into 2025, the automotive industry continues to experience unprecedented transformation. The chassis—historically perceived as a mechanical foundation—has evolved into a sophisticated, integrated system that responds to the megatrends reshaping our industry. As Chair of the FISITA Advanced Chassis Technology Expert Group, I observe how our collective engineering approach must adapt to meet these emerging challenges and opportunities.
Megatrends reshaping chassis engineering
The electrification revolution has fundamentally altered chassis design requirements. Electric vehicles, with their lower centres of gravity and unique weight distributions, demand reconfigured suspension systems, specialized brake solutions, and enhanced structural integration. The battery pack’s substantial mass has forced engineers to rethink load paths and dynamic behaviour throughout the chassis system.
Concurrently, connectivity and autonomous capabilities are redefining our approach to vehicle dynamics. Chassis systems now serve as both physical foundations and as platforms for sensor integration, enabling real-time environmental awareness. The modern chassis must not only manage mechanical forces but also support the digital infrastructure required for connected mobility.
Those engineering teams that successfully navigate this convergence will define the next generation of mobility solutions, creating chassis systems that are not merely platforms for transportation but intelligent foundations for the connected, autonomous, and sustainable vehicles of tomorrow
Smart vehicle technologies have introduced new complexities in harmonizing multiple chassis subsystems. The integration of active suspensions with steering assistance and advanced braking systems requires sophisticated control strategies beyond traditional mechanical engineering approaches.
The data revolution in chassis development
Artificial intelligence has revolutionized how we approach chassis optimization. Machine learning algorithms now analyse vast datasets from road tests, allowing us to identify patterns and relationships that would elude conventional analysis. AI-driven optimization has enabled us to achieve performance improvements within increasingly tight regulatory constraints.
Real-time data collection from production vehicles provides unprecedented insights into chassis behaviour under genuine operating conditions. This wealth of information allows engineering teams to develop more sophisticated simulation models and implement predictive maintenance protocols that were previously impossible.
The integration of digital twins with physical testing has accelerated development cycles while improving outcome quality. By maintaining synchronized digital representations of physical chassis systems, we can rapidly iterate designs and predict behaviours across a wider range of conditions than physical testing alone would permit.
Emissions and regulatory challenges
The Euro 7 standards, expected to be fully implemented by 2026, have placed significant focus on non-exhaust emissions—particularly those from brakes and, in the near future, tyres. Particulate matter generated during braking events now faces strict limitations, driving the development of new materials for brake friction couples, and enhanced regenerative braking strategies that substantially reduce wear.
The integration of chassis systems with other vehicle domains requires sophisticated domain controllers and standardised communication protocols. The engineering challenge has expanded beyond mechanical optimisation to include software architecture design and cybersecurity considerations
Tyre wear particles, identified as significant pollutants, are receiving intensified regulatory attention. This has accelerated research into advanced compound formulations that maintain performance while reducing environmental impact. The engineering challenge lies in balancing reduced emissions with maintained safety performance and durability.
Testing methodologies have evolved to address these new regulatory requirements. Advanced particulate measurement systems and standardised test protocols are becoming essential elements of chassis development programmes. Our engineering approach must now incorporate these non-exhaust emissions concerns from the earliest design stages rather than as afterthoughts.
Virtualisation: The new engineering paradigm
Simulation technologies have transformed chassis development by enabling comprehensive optimisation before physical prototypes exist. Multi-body dynamics simulations, coupled with finite element analysis, allow engineers to predict complex interactions between chassis components with unprecedented accuracy.
Hardware-in-the-loop testing extends these capabilities by incorporating actual components into virtual environments. This approach is particularly valuable for evaluating control systems for active chassis components, enabling exhaustive testing under conditions that would be dangerous or impractical to recreate physically.
Cloud-based simulation platforms have democratised access to sophisticated analysis tools, allowing distributed engineering teams to collaborate effectively on chassis development. The ability to run thousands of simulation scenarios in parallel has compressed development timelines while expanding exploration of the design space.
Software-defined vehicles and chassis integration
The emergence of software-defined vehicle architectures has fundamentally altered chassis system design. Active systems now operate within integrated control frameworks rather than as isolated subsystems. This integration enables more sophisticated responses to dynamic driving conditions through coordinated actions across multiple chassis components.
Artificial intelligence has revolutionized how we approach chassis optimization. Machine learning algorithms now analyse vast datasets from road tests, allowing us to identify patterns and relationships that would elude conventional analysis
Over-the-air update capabilities extend the evolution of chassis performance throughout the vehicle lifecycle. Suspension systems can be refined, stability controls enhanced, and braking performance optimised without requiring physical modifications. This continuous improvement model represents a significant departure from traditional chassis engineering practices.
The integration of chassis systems with other vehicle domains requires sophisticated domain controllers and standardised communication protocols. The engineering challenge has expanded beyond mechanical optimisation to include software architecture design and cybersecurity considerations for these critical systems.
Mechanical expertise meets data science, software, and sustainability
The transformation of chassis technology represents both a challenge and an opportunity for engineering teams. As complexities increase, so does our ability to create more capable, efficient, and sustainable solutions. The future of chassis engineering lies not only in mechanical innovation but in the seamless integration of physical systems with digital capabilities.
Our industry stands at an inflection point where traditional mechanical expertise must merge with data science, software engineering, and environmental consciousness. Those engineering teams that successfully navigate this convergence will define the next generation of mobility solutions, creating chassis systems that are not merely platforms for transportation but intelligent foundations for the connected, autonomous, and sustainable vehicles of tomorrow.
About the author
Fabio Squadrani is Senior Manager, Braking Systems at Applus IDIADA
To learn more about the FISITA Advanced Chassis Technology Expert Group, visit the FISITA website (https://fisita.com/community/expert-groups/), or contact FISITA CTO Martin Kahl [email protected]