Abstract: A recyclable, low cost, collision-resistant automobile chassis and body and method for fabricating the same. The method of manufacture comprises; fabricating a plurality of generally planar bulkheads from a metal alloy; disposing the bulkheads in a generally and mutually parallel orientation, each bulkhead perpendicular to and aligned generally transversely and symmetrically relative to a common central horizontal longitudinal axis; fabricating a plurality of chassis segments from the metal alloy, each segment comprising a multiplicity of spaced hollow cells fixed at one end in a common surface; interposing and rigidly attaching at least one of said pluralities of chassis segments between respective bulkheads to form a plurality of chassis sections, a section defined as the portion of the fabricated chassis between two adjacent bulkheads; and permeating the plurality of chassis sections with liquefied polymer between and around said hollow cells.

Abstract: An automobile chassis and a one-piece body integrated into a unitary structure, and a method for fabricating, assembling and integrating the chassis and body. The body includes interior panels, a cockpit, an engine enclosure module, and an underbody. The chassis/body structure, comprised of a single type of aluminum alloy and a single type of thermoplastic, is resistant to high-stress loads and is substantially recyclable into industrial-quality constituents. A first preferred embodiment includes a body rotomolded from a reinforced polycarbonate, polycarbonate/ABS blend, or polyimide thermoplastic, seven aluminum alloy bulkheads, and stacks of thin-wall aluminum honeycomb-cell panels embedded in an unreinforced foam of the thermoplastic. A second preferred embodiment includes a body rotomolded from a reinforced liquid crystal polymer thermoplastic, seven aluminum alloy bulkheads, and stacks of thin-wall aluminum honeycomb panels.