Analyse
Use CFD-derived geometry to understand the aerodynamic intent and key surfaces.
AERODYNAMICS · DFM · COMPOSITES
FORMULA STUDENT AERO PACKAGE
Design, manufacture and optimisation of the University Formula Student team's inaugural aerodynamic package.
PROJECT OVERVIEW
Turning CFD surfaces into manufacturable aerodynamic components.
As a first-year member of the University's Formula Student team, I contributed to the development of the car's inaugural aerodynamic package.
My work focused on the design-for-manufacture process, taking aerodynamic surfaces developed through CFD and adapting them into components that could be manufactured reliably.
This included research into carbon-fibre manufacturing techniques, CAD development of mould tooling, structural optimisation and performance validation.
DEVELOPMENT PROCESS
From aerodynamic surface to manufactured component.
Adapt
Modify the design to satisfy manufacturing, packaging and structural requirements.
Manufacture
Develop mould tooling and composite manufacturing proposals for the wing elements.
Validate
Use simulation and vehicle-level modelling to assess the expected performance benefit.
01
AERODYNAMIC DEVELOPMENT
Inaugural Aero Package
The project involved contributing to the team's first complete aerodynamic package, requiring the transition from CFD-driven surfaces into practical component designs.
- Worked from surfaces developed within CFD.
- Supported aerodynamic development using STAR-CCM+.
- Assessed how aerodynamic geometry could be adapted for manufacture.
- Considered component integration within the wider vehicle package.
DESIGN FOR MANUFACTURE
The fastest aerodynamic surface is only useful if it can be built.
02
DESIGN FOR MANUFACTURE
From CFD Geometry to Production
A major focus of the project was adapting aerodynamic geometry so that the final components could be manufactured using realistic processes and tooling.
- Led the design-for-manufacture process for wing components.
- Researched a range of carbon-fibre manufacturing techniques.
- Refined component geometry around manufacturing limitations.
- Created negative mould geometry using Fusion 360 and CATIA.
- Considered repeatability, stiffness and production practicality.
03
STRUCTURAL OPTIMISATION
Weight Reduction
Structural optimisation was used to reduce unnecessary material while maintaining sufficient stiffness and strength within the aerodynamic components.
04
STRUCTURAL DESIGN
Internal Rib Structure
Internal rib structures were incorporated to increase stiffness without relying solely on additional external material.
- Developed a lightweight internal rib arrangement.
- Increased structural stiffness of the wing assembly.
- Considered local reinforcement around critical interfaces.
- Balanced structural performance against mass reduction.
05
COMPONENT ASSEMBLY
Wing Construction
The component architecture was developed as an assembly, combining aerodynamic skins, structural inserts and internal reinforcement into a manufacturable wing structure.
PROJECT REFLECTION
Designing for performance and manufacture.
This project developed my understanding of the compromises required when turning aerodynamic concepts into components that can be manufactured reliably.
It strengthened my experience across CAD, CFD and design for manufacture, while demonstrating the importance of considering aerodynamic performance, structural design and manufacturing constraints together.