The Process

The aerodynamic wing assembly was developed through an iterative design and validation process integrating CAD modeling, computational fluid dynamics, physical testing, and composite manufacturing. The wing geometry was first modeled in SolidWorks, enabling parametric adjustments and integration with the vehicle mounting structure. Aerodynamic performance was evaluated using ANSYS Fluent and Autodesk CFD to simulate airflow behavior and estimate downforce and drag characteristics across the wing elements. These simulations informed design refinements to improve aerodynamic efficiency and balance. Experimental validation was conducted using shock potentiometers, strain gauges, and an accelerometer to measure suspension displacement, structural strain, and dynamic vehicle response under aerodynamic loading. The final design was manufactured using a lightweight composite construction. The main planes were fabricated with a foam core layup reinforced by continuous carbon fiber rods and aluminum spars to provide stiffness while minimizing weight. The endplates were produced separately and vacuum bagged to ensure proper fiber consolidation and structural integrity. This workflow enabled the wing to be optimized for aerodynamic performance, structural reliability, and manufacturability.