Case Study: King Abdullah University of Science and Technology achieves breakthrough aerodynamic visualization and front-wing optimization with Stratasys 3D printing

Revolutionizing Race Car Aerodynamics with Supercomputing and 3D Printing

King Abdullah University of Science and Technology (KAUST) needed to visualize and interpret large, complex CFD outputs from the Shaheen XC40 supercomputer to optimize a Formula One front wing endplate for improved downforce and lap‑time performance. To turn simulation data into tangible insights, KAUST partnered with Stratasys and used the Stratasys PolyJet™ J‑Series 3D printer via its Prototyping and Product Development Core Lab (PCL).

Stratasys produced full‑color, multi‑material 3D prints that directly colored flow patterns on the wing, delivering Schlieren‑style visualizations without post‑processing. Those realistic physical models let KAUST researchers clearly see key flow features from their AANSLab simulations, speeding interpretation and design iteration and supporting aerodynamic improvements that can translate into the small, race‑deciding performance gains (e.g., around 1%) targeted in Formula One. Stratasys’ technology therefore enabled clearer, faster optimization of the wing design.

King Abdullah University of Science and Technology

Matteo Parsani

Professor