Challenges and Strategies in Bridging Aerodynamic Research with Industrial Prototyping: Insights from Formula and Luxury Automotive Design
Keywords:
automotive aerodynamics, design-engineering integration, digital twin optimizationAbstract
This paper investigates the challenges and strategies in bridging aerodynamic research with industrial prototyping, using Formula racing and luxury automotive design as comparative case studies. While Formula cars prioritize downforce, adjustability, and lightweight efficiency, luxury vehicles emphasize low drag, aesthetic integration, and customer perception. The study identifies key barriers such as late-stage aerodynamic integration and cross-disciplinary misalignment. A generalized framework is proposed, highlighting early-stage simulation-styling fusion, multi-objective optimization, and closed-loop validation. Future directions include AI-driven design platforms, cross-sector collaboration, and sustainable aerodynamic optimization. The findings offer insights for both researchers and industry practitioners aiming to accelerate aerodynamic innovation.References
1. Z. Mohamed-Kassim, and A. Filippone, "Fuel savings on a heavy vehicle via aerodynamic drag reduction," Transportation Research Part D: Transport and Environment, vol. 15, no. 5, pp. 275-284, 2010. doi: 10.1016/j.trd.2010.02.010
2. S. H. A. S. Banuri, U. Qayyum, K. R. Qureshi, and A. Ahmed, "Investigation of drag coefficients for various car models," In 2020 17th International Bhurban Conference on Applied Sciences and Technology (IBCAST), January, 2020, pp. 467-471. doi: 10.1109/ibcast47879.2020.9044503
3. X. Jin, S. Yan, Q. Wang, S. Deng, Y. Jiang, and S. Zhao, "A Closed-Loop Multi-Agent Framework for Aerodynamics-Aware Automotive Styling Design," arXiv preprint arXiv:2508.03370, 2025.
4. F. Di Fiore, D. Quagliarella, and L. Mainini, "On the Usefulness of Multiple Levels of Fidelity: Investigation and Preliminary Considerations for Aerodynamic Design," In AIAA AVIATION FORUM AND ASCEND 2024, 2024, p. 3980. doi: 10.2514/6.2024-3980
5. W. Toet, "Aerodynamics and aerodynamic research in Formula 1," The Aeronautical Journal, vol. 117, no. 1187, pp. 1-26, 2013. doi: 10.1017/s0001924000007739
6. J. Katz, "Aerodynamics of race cars," Annu. Rev. Fluid Mech, vol. 38, no. 1, pp. 27-63, 2006. doi: 10.1146/annurev.fluid.38.050304.092016
7. S. Rijns, T. R. Teschner, K. Blackburn, E. Siampis, and J. Brighton, "Optimising vehicle performance with advanced active aerodynamic systems," Vehicle System Dynamics, pp. 1-29, 2025.
8. M. Elrefaie, J. Qian, R. Wu, Q. Chen, A. Dai, and F. Ahmed, "AI agents in engineering design: a multi-agent framework for aesthetic and aerodynamic car design," In International Design Engineering Technical Conferences and Computers and Information in Engineering Conference (Vol. 89237, p. V03BT03A048). American Society of Mechanical Engineers., August, 2025. doi: 10.1115/detc2025-169682
9. F. Moëns, "A fast aerodynamic model for aircraft multidisciplinary design and optimization process," Aerospace, vol. 10, no. 1, p. 7, 2022. doi: 10.3390/aerospace10010007
10. J. Smeets, K. Öztürk, and R. Liebich, "Digital twins for automotive development: Two wheelers application," Advanced Engineering Informatics, vol. 56, p. 101982, 2023. doi: 10.1016/j.aei.2023.101982
11. N. Bhagat, S. Kant, and A. Tiwari, "ADVANCED TOOL FOR FLUID DYNAMICS-CFD AND ITS APPLICATIONS IN AUTOMOTIVE, AERODYNAMICS AND MACHINE INDUSTRY," Technology, vol. 7, no. 2, pp. 177-186, 2016.
12. D. Ergashev, "CFD AND EXPERIMENTAL TESTING IN VEHICLE AERODYNAMICS," International Journal of Artificial Intelligence, vol. 1, no. 4, pp. 801-806, 2025.
13. T. C. Schuetz, "Aerodynamics of road vehicles," Sae International, 2015.
14. S. Mansor, N. A. R. Nik Mohd, and C. W. Chung, "Validation of CFD modeling and simulation of a simplified automotive model," Applied Mechanics and Materials, vol. 735, pp. 319-325, 2015.
15. B. D. Duncan, S. Senthooran, D. Hendriana, P. Sivakumar, D. Freed, M. Gleason, and D. C. Hall, "Multi-disciplinary aerodynamics analysis for vehicles: application of external flow simulations to aerodynamics, aeroacoustics and thermal management of a pickup truck (No. 2007-01-0100)," SAE Technical Paper, 2007.
16. P. G. Wright, "The influence of aerodynamics on the design of Formula One racing cars," International Journal of Vehicle Design, vol. 3, no. 4, pp. 383-397, 1982.
17. M. A. Dharmawan, N. Ubaidillah, W. A. A., and N. A. T., "Aerodynamic analysis of formula student car," In AIP Conference Proceedings, February, 2018, p. 030048.
18. P. Singh, V. Raghavender, S. Joshi, N. P. Vasant, A. Awasthi, A. Nagpal, and A. jasim Abd al-saheb, "Composite material: A review over current development and automotive application," Materials Today: Proceedings, 2023.
19. S. A. Renganathan, K. Harada, and D. N. Mavris, "Aerodynamic data fusion toward the digital twin paradigm," AIAA journal, vol. 58, no. 9, pp. 3902-3918, 2020. doi: 10.2514/1.j059203
20. F. Bellalouna, "Case study for design optimization using the digital twin approach," Procedia CIRP, vol. 100, pp. 595-600, 2021. doi: 10.1016/j.procir.2021.05.129
21. A. Raveendran, S. N. Sridhara, D. Rakesh, and S. R. Shankapal, "Exterior styling of an intercity transport bus for improved aerodynamic performance (No. 2009-28-0060)," SAE Technical Paper, 2009.
22. J. Piechna, "A review of active aerodynamic systems for road vehicles," Energies, vol. 14, no. 23, p. 7887, 2021. doi: 10.3390/en14237887
23. T. Müller, C. Gold, A. Eichinger, and K. Bengler, "Identifying customer-oriented key aspects of perception with focus on longitudinal vehicle dynamics," In 4th International Conference on Human Factors and Ergonomics., July, 2012.
24. R. Yondo, K. Bobrowski, E. Andrés, and E. Valero, "A review of surrogate modeling techniques for aerodynamic analysis and optimization: current limitations and future challenges in industry," Advances in evolutionary and deterministic methods for design, optimization and control in engineering and sciences, pp. 19-33, 2018. doi: 10.1007/978-3-319-89988-6_2
25. S. Sahibzada, F. S. Malik, S. Nasir, and S. K. Lodhi, "Generative AI Driven Aerodynamic Shape Optimization: A Neural Network-Based Framework for Enhancing Performance and Efficiency," International Journal of Innovative Research in Computer Science and Technology, vol. 13, no. 1, pp. 98-105, 2025. doi: 10.55524/ijircst.2025.13.1.15
26. Z. el Nabolsy, "The Importance of Aesthetic Considerations in Engineering Design," .
27. A. Amrit, L. Leifsson, and S. Koziel, "Design strategies for multi-objective optimization of aerodynamic surfaces," Engineering Computations, vol. 34, no. 5, pp. 1724-1753, 2017. doi: 10.1108/ec-07-2016-0239
28. G. Döllner, P. Kellner, and O. Tegel, "Digital mock-up and rapid prototyping in automotive product development," Journal of Integrated Design and Process Science, vol. 4, no. 1, pp. 55-66, 2000. doi: 10.3233/jid-2000-4104
29. P. Zhang, J. Gao, and Y. Wang, "Requirement driven knowledge management system design to support automotive product development," International Journal of Product Lifecycle Management, vol. 5, no. 2-4, pp. 202-223, 2011.
30. P. S. Palar, Y. B. Dwianto, L. R. Zuhal, J. Morlier, K. Shimoyama, and S. Obayashi, "Multi-objective design space exploration using explainable surrogate models," Structural and Multidisciplinary Optimization, vol. 67, no. 3, p. 38, 2024. doi: 10.1007/s00158-024-03769-z
