Automotive Aerodynamics

The second prototype simplified and strengthened features of the outer shell. The design needed to be light weight, therefore I has to allocate rigid structures in places of stress and force transfer. Overall the design has less surface area. A redundant feature I kept was the vertical stabilizer, Co2 cars are constrained to a cable which already provide vertical stability. Lastly, the rear wheels were covered to ease assembly. 

The sectioned render provides view to the internal features. The shell was created to require no support material. When printed on it's rear face, overhanging features can be compensated using a bridge feature. Usually, thin 3d printed design have most of their weight concentrated in their walls. As such, the second design has 2 layer thick walls. (each layers being around 0.4mm thick). Though, a design of this thickness is near the limit of a functioning part. The frame (in yellow) is fastened to the bottom of the shell. To it, the bearings, axles, and wheels are fixed.