motorsport
Case Study Insight
Creating a Motorsport roll cage without welding or drilling into the Alfa Romeo 4C’s carbon monocoque was a high-stakes challenge. Through precision laser scanning, adhesive bonding and FIA-approved design, our team engineered a fully compliant ROPS that met rigorous homologation standards — without compromising the integrity of the car’s structure.
Full Case Study
In 2019, we embarked on one of our most technically demanding projects: developing the A018 weld-in roll cage for the Alfa Romeo 4C.
The primary challenge lay in the vehicle’s carbon monocoque construction, which prohibits traditional welding or drilling for roll cage installation. To overcome this, we began by capturing highly detailed laser scan data to model bespoke ROPS mounting plates for a perfect fit. After extensive surface preparation, the plates were bonded to the monocoque using a specialist two-part structural adhesive — eliminating the need for any mechanical fasteners. Their positioning was verified with Coordinate Measuring Machine (CMM) technology before being clamped into place for a 7-day curing process. Once cured, our engineering team used the scan data to optimise the roll cage design for both performance and compliance. The final structure was precision TIG welded and successfully passed FIA homologation testing.
This project stands as a testament to innovation under constraint, proving that safety, performance and preservation of factory design can coexist.
Further Information
For further information on our Motorsport capabilities, please visit our Motorsport Sector.
Related Capabilities
Speak to an Expert
For further information on our products and services, please use the contact details below, or submit an enquiry through the online form, and our dedicated team will be on hand to assist you.
Phone+44 (0)1638 713 606
Opening Hours09:00 - 17:00
Monday - Friday
Holborn Ave
Mildenhall
Suffolk
IP28 7AN
United Kingdom
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Safety Devices have defined the standards of roll-over protection for over 50 years, establishing ourselves as the world’s most trusted designers and manufacturers in the industry.
50+ Years
With over 50 years of experience, we blend cutting edge engineering with a rich heritage. Setting the standard for safety with a legacy that began in the mid-1960s, when John Aley of Aley Bars introduced the first roll cages to European motorsport.
Design Excellence
Our wealth of knowledge, experience and knowhow result in roll over protection systems designed to the highest standard. Enhancing both safety and performance with our modern design principles and rigorous engineering, frequently tested by our customers in real world incidents.
Quality Assurance
We are renowned for the quality of our products using only the finest, traceable materials, and offer proven capability and resources to fabricate roll over protection solutions and accessories. To ensure that our products meet the highest standards for a wide range of project needs, Safety Devices are ISO9001 certified.
Worldwide Solutions
From high-octane motorsport to rugged expedition vehicles, essential fleet operations, dynamic construction sites and specialised military requirements, we offer products and engineering solutions for multiple industries across the world.
Largest Product Range
Universally accepted as the leading manufacturer of roll cages, we offer a growing range of roll over protection solutions for more than 2,500 vehicles. We also offer a specialist range of roof racks, vehicle bumpers, racing harnesses and more through our accessories shop and trusted dealers.
Advice & After Sales
Committed to providing expert advice at every stage, we pride ourselves on our exceptional customer service and continued after sales support.
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FAQs
If you have questions that needs answers our FAQs could be just what you need. If you can’t find what you’re looking for we have a team of experts that can help you, just click below.
Who are Safety Devices?
Safety Devices International Ltd are a British owned company specialising in the design and manufacture of roll over protection products. With over 50 years of experience, we have become the world’s most trusted designers and manufacturers in the industry.
What is a roll cage or ROPS?
A roll cage or ROPS (Roll Over Protection System) is an internal or external structure installed on a vehicle, designed to protect vehicle occupants by preserving survival space during a rollover incident.
Do you offer bespoke roll cages?
Yes, we can offer bespoke products. For more information, please visit our Capabilities Pages.
Are your ROPS built to certain standards?
We offer two tiers of standard ROPS for 4×4 vehicles.
Our Heavy Duty option represents the highest specification, providing impressive strength (minimum gross vehicle weight -7.5x vertically, 5.5x longitudinally and 1.5x laterally). It is a higher grade for use in oil and gas exploration, meeting international standards.
In contrast, our Safety Devices General Purpose ROPS are designed with slightly reduced strength specifications and components, yet remain suitable for a wide range of applications.
Can I buy products directly from Safety Devices?
Yes, well sell directly to companies and other organisations within the Automotive, Fleet, Construction and Military sectors.
Do Safety Devices offer roll cage installation?
Yes, we do offer on-site roll cage installations, however these are dependent on our workshop availability. For a quotation, please contact our sales team who can assist your further.