The honeycomb structural element can withstand the higher payload when compared to solid structure for the same chassis weight. With the basic shapes of honeycomb structure such as Triangular(Tetra-hedral), Rectangular (Parallelogram), and Hexagon, the core units of chassis are designed and Finite Element Analysis will be done through Ansys Software. From the results of Shear, compressive loads and displacement by the mentioned stresses are validated and the optimum model of chassis honeycomb structure will be developed by aligning them symmetrically on two perpendicular directions on welding process. This structure forms a honeycomb panel. Thus these developed honeycomb panels are used to develop the chassis frame of a buggy vehicle.