Case Study: Agoria Solar reduces wind-tunnel costs and validates aerodynamics with Materialise 3D-printed scale models

Reducing the Cost of Wind Tunnel Testing with 3D-Printed Models

Agoria Solar, the student solar‑car team from KU Leuven, needed an affordable way to validate aerodynamic simulations without the expense of full‑scale wind tunnel time. They partnered with Materialise to produce a precise scale replica of their car for smaller‑tunnel testing, using 3D printing via stereolithography (SLA).

Materialise designed and delivered an 80 cm SLA scale model with adjustable parts (including a movable canopy) within six weeks, enabling 0–10° crosswind tests and Reynolds scaling to extrapolate results to the full vehicle. The 3D‑printed model revealed simulation inaccuracies, validated aerodynamic trends before full‑scale testing, smoothed the full test workflow, and saved time and cost compared with immediate full‑scale testing.

Agoria Solar

Zander Radelet

Aerodynamicist