A Go-Kart is a four-wheeled vehicle having low ground clearance and does not involve a differential and suspension. The present study focuses on the analysis of an electric Go-Kart chassis frame based on proper material selection and optimized chassis thickness. To find the optimum material and thickness, a comparative analysis was conducted with three different materials, namely AISI 1018, AISI 1020 and AISI 4130, which were selected based on their yield tensile strength values. Similarly, the effect of stress on thickness variation of the chassis is analysed by varying the thickness values between 1.4 and 2 mm in a step of 0.2 mm. From the numerical studies, the results show that the AISI 1018 is the suitable material based on the factor of safety, weldability and machinability. Optimizing the thickness of the chassis helps chassis weight and cost reduction. © 2022, The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.