A patented, one-piece, fiber-reinforced plastic composite chassis, produced by sheet molding compression, uses a highglass-content vinyl ester composite structural material, toughened with urethane for fatigue and damage tolerance.The part minimizes secondary operations and limits the use of steel supports. The chassis, which includes intrinsic corrosion resistance, reduces the part count to one molded piece. Moreover, the flexibility in composite design allows the molding of different features and the customizing of a vehicle for different uses and power trains. The elimination of welded joints and the implementation of rounded transitions also contribute to the structural integrity of the component. During durability testing, the composite chassis went through three lifetime tests without any failure.