Aerodynamics / CAD / Composite manufacturing
Formula Student — Carbon Fiber Front Wing
Aerodynamic development, CAD design, composite moulds and manufacture of a carbon-fiber front wing for a Formula Student race car.
Application
Formula Student race car
Simulation
Simcenter STAR-CCM+ CFD
Tools
Fusion 360 / Creo / Composite moulds
Engineering case study
Project overview
The project covered the development and manufacture of a carbon-fiber front wing for a Formula Student race car, connecting aerodynamic simulation with CAD modelling, composite tooling and final integration.
The work included CFD simulation in Simcenter STAR-CCM+, CAD and mould development in Creo and Fusion 360, and manufacture of aerodynamic surfaces and a carbon-fiber spar.
Design / Realization
From CAD to reality.
Compare the design model with the completed physical result.
Engineering development
Project image gallery
Additional project views, CAD development images and supporting material.
Project specifications
Technical details
- Engineering software
- Fusion 360, Creo, Simcenter STAR-CCM+
- Analysis
- Computational fluid dynamics (CFD)
- Manufacturing
- Carbon-fibre composite tooling and layup
- Structure
- Carbon-fibre spar with water-jet-cut aluminium ribs
Aerodynamics and CAD
CFD simulations were performed in Simcenter STAR-CCM+ before the design was finalized. The aerodynamic geometry was then developed into CAD models suitable for tooling and assembly planning.
- Aerodynamic concept assessment with CFD
- CAD surfaces and structural geometry
- Composite mould modelling
- Manufacturing and integration planning
Composite manufacturing
The aerodynamic surfaces and the carbon-fiber spar were manufactured using custom moulds. Water-jet-cut aluminium ribs were integrated to maintain the intended wing profile and structural stiffness.
Final work included assembly and integration of the completed front wing onto the vehicle.
Engineering takeaway
The case demonstrates the importance of bringing aerodynamic design, manufacturing constraints and assembly details together. Each phase affects whether the intended geometry can be realized in physical composite components.
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