An All-Terrain Vehicle (ATV) roll cage is a structural arrangement that gives three-dimensional protection for the driver in the event of a rollover or abrupt impact accident, while also supporting the subsystems. In order to ensure that an ATV is structurally well-balanced and can protect the driver from impacts from the terrain, it should meet regulations with a proven design, few structural elements, light weight, great strength, and should be tested for unexpected impact loading. The objective of present work is to formulate a conceptual design followed by analysis of roll cage of robust 3-seater ATV need to be fabricated by CSMT, Tekanpur for the BSF frontiers at creeks of Gujarat. Ansys student 2024 R1 is used for analysis under defined constraints like front, side and rear impact on the roll cage. Three types of materials AISI 4130, AISI 1020 (DOM), and AISI 1018 are used for comparative analysis of crash test. This work provides the well-studied and optimal design approach on ATV roll cage to improve its impact bearing capability with better weight reduction and enriched strength ratio for a long duration. The research aims to give an introduction to the material selection procedure that need to be done before finalizing the design, using FEA software. In present work, various factors such as impact force calculations, loading points, generated Von-Misses Stress, deformation and Factor of Safety (FOS) are studied. The result of Finite Element Analysis (FEA) simulation showed least stress and deformation with highest factor of safety to suggests AISI 4130 as best suitable material for fabrication of roll cage