Case Study: BMI Corporation achieves race‑winning aerodynamic gains for NASCAR teams with 3D Systems' Geomagic Design X

3D Scanning and Reverse Engineering with Geomagic Design X Helps NASCAR Cars Race to Victory

BMI Corporation and its sister company Advanced Vehicle Research (AVR) provide aerodynamic and CFD expertise to NASCAR teams, led by Boeing veteran Michael Henderson. Facing NASCAR’s tight templates and handmade car variations—where tiny geometric differences can decide races—AVR needed a precise, repeatable way to capture every surface, especially the undercarriage that creates downforce, because traditional wind-tunnel data can be off by large margins.

AVR combines a Konica Minolta 3D laser scanner with 3D Systems’ Geomagic Design X to capture ~150 scans (≈20 million points, filtered to ~5 million), align and heal the data, and create parametric NURBS CAD models for CFD. This workflow reveals minute adjustments that translate to real-world gains (e.g., a 5% drag reduction ≈ 25 hp equivalent or a 0.1 increase in downforce coef. ≈ +1.8 mph lap speed), gives teams a measurable competitive edge, and is validated on track and in wind tunnels—critical for current cars and the stricter Car of Tomorrow.

BMI Corporation

Michael Henderson

Co-Founder