Scan2Carbon
End-to-End Aerodynamic Development – From Concept to Carbon Part
StageOne Composites offers a complete development and production chain for aerodynamic vehicle components – precise, efficient, and motorsport-proven.
With Scan2Carbon, you get a complete, end-to-end solution – from 3D scanning to the production of optimized aerodynamic carbon fiber parts.
01
3D Vehicle Scan
Goal: Precise digital replica of the vehicle as a foundation for all further steps.
Technology: Optical 3D scanner (Structed Light Scan: Infrared, Depth and RGB Cameras).
Result: High-resolution data up to 0.1 mm point distance (OBJ, STL, PLY, P3, 3MF), ready for CAD import.
02
CAD Modeling
Goal: Creation of a simplified but accurate CAD model for CFD analysis.
Technology: Reverse engineering & surface reconstruction.
Result: Solid model for aerodynamic evaluation and design baseline.
03
CFD Simulation
Goal: Determining aerodynamic baseline data (e.g., lift, drag, balance).
Technology: Computational Fluid Dynamics (OpenFOAM).
Result: Front balance, Cl/CD values, pressure maps as a benchmark for optimization.
Design of Aero Components
04
Goal: CAD development of parts like splitters, canards, spoilers, or diffusers.
Approach: Performance-oriented motorsport design – not just aesthetics, but function.
Note: Each part is tailored to the vehicle, use case, and regulations.
05
CFD Simulation with Aero Upgrades
Goal: Validation and optimization of the new aerodynamic components.
Comparison: Direct before/after comparison with the stock model.
Outcome: Simulation of real effects like downforce, balance shifts, flow separation.
06
3D Printing of Prototypes
Goal: Production of test parts for form fitting, test mounting, or initial track testing.
Material: High-strength plastics (e.g., ASA, PETG, CF-reinforced nylon).
Advantage: Fast iteration before final carbon production – design changes easily implemented.
Manufacturing of Final Carbon Parts
Goal: Production of final components in motorsport-grade carbon fiber.
Process: Vacuum infusion or prepreg – depending on part and volume.
Features:
- Lightweight & high-strength
- Heat-resistant resins for motorsport use
- Optional: Painted or clear-coated carbon finish
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