Case Study: Aptera Motors achieves record-breaking EV efficiency with AirShaper AI Morphing

Aptera Motors boosts EV efficiency 4x with AirShaper

Aptera Motors, an electric vehicle manufacturer, aimed to build an extremely aerodynamic and efficient solar-assisted car. The challenge was to make the most aerodynamic vehicle possible from the start, which required minimizing drag without sacrificing passenger space, structural integrity, or manufacturability to achieve record-breaking efficiency targets. To tackle this, they turned to vendor AirShaper for aerodynamic analysis and optimization.

The solution from AirShaper involved an initial phase of CFD analysis followed by the use of their AI Morphing tool. This generative design approach algorithmically refined the vehicle's shape in key areas like the wheel covers, nose, and tail, leading to non-obvious improvements. As a result, Aptera Motors achieved a 6% reduction in drag coefficient, which contributed to a final vehicle that is four times more efficient than the average EV, consumes under 100 Wh/mile, and supports a lower battery cost.

Aptera Motors