MillenWorks body systems are designed to meet stiffness, weight, blast/ballistic protection, production cost, aerodynamic, and aesthetic requirements. These systems utilize a variety of materials and manufacturing techniques including formed thin steel sheet, rolled homogenoues armor (RHA) or High Hard Steel (HHS), formed and cut laminated glass, and advanced composites. Our interiors are designed to suit the particular application, be it NBC washdown and black-out compatibility for military vehicles, sumptuous leather and noise insulation for our refined concept vehicles, or utilitarian and safe for our racing vehicles.

MillenWorks has developed both structural and non-structural components utilizing a variety of different composite materials. These materials include fiberglass, carbon, and carbon/aramid-fiber (Kevlar) fabrics, fiber reinforced plastics (FRPs), and honeycomb made from aluminum, fiberglass, and Kevlar. Fabrication processes include hard tooling, hand layup, and pre-preg and, when necessary, computer controlled cure in an autoclave.

MillenWorks integrates armor materials into new and existing vehicles as needed to meet ballistic and blast protection requirements. We are constantly working with new armor material manufacturers to understand which materials are best suited to different requirements (threat level, cost, weight, etc.). There is more to providing a survivable system than just welding armor plate to a vehicle. MillenWorks provides thoroughly engineered systems that perform to specification for years.

MillenWorks employs advanced motion controls and optimized strucutral and kinematics design to provide vehicles with complex body closures. These closures include automated doors, sunroofs, hatches, and spoilers. In many cases these involve motions in several different directions which must be carefully synchronized to provide the correct functionality as well as to avoid interference with other vehicle components.