Case Study: Stewart-Haas Racing achieves successful NASCAR wind tunnel submission testing with 3D Systems SLA printing

SLA Machines Enable the Successful Wind Tunnel Submission Testing of the 2024 NASCAR Ford Mustang Dark Horse

Stewart Haas Racing, a NASCAR Ford racing team, faced the challenge of efficiently testing hundreds of aerodynamic body panel designs for its 2024 Mustang Dark Horse. Full-scale wind tunnel testing is extremely expensive, so the team needed a rapid and reliable method to physically produce numerous concepts between sessions to find the optimal performing shape.

The solution was implemented using 3D Systems’ SLA printers and 3D Sprint software. This technology allowed the team to quickly convert CFD models into high-quality, smooth-finish 3D printed parts that were assembled onto a test car for wind tunnel evaluation. The reliability of 3D Systems’ machines was crucial for printing hundreds of large parts on a tight schedule. This process enabled Stewart Haas Racing and Ford to successfully optimize and submit a body shape that met all NASCAR specifications, resulting in a race-winning car capable of competing for a NASCAR Cup Series championship.

Stewart Haas Racing