3D printed rear wing system "WING3D" facilitates active aerodynamics
Rear wing systems for active aerodynamics are characterised by high functional requirements, kinematics, a high number of components, and high tooling investments. In the OptiAMix research programme, we, in cooperation with eight partners, worked out ways of optimising these problems and demonstrated the results in the WING3D rear wing system. The project was sponsored by the German Federal Ministry of Education and Research (BMBF).
New, efficient CAx methods in the development process and the use of additive manufacturing resulted in the creation of a lightweight rear wing which also meets the high structural requirements of real-life applications. There was also a focus on improved aerodynamic properties and a visually appealing design.
With the knowledge gained from the project, it is possible for the potential of additive manufacturing to be raised by using an adapted development process. This is characterised by elements that have been tailor-made for additive manufacturing: component selection with potential analysis, new design guidelines, definition of mechanical properties, product protection, coordination of the process and multi-objective optimisation of component design in terms of topology optimisation, support structure, finishing processes and build direction.
Are you on the look-out for lightweight design solutions or ways of manufacturing body parts by means of 3D printing? Sebastian Flügel looks forward to hearing from you.