The Sebar Monocoque
A minimalist, performance-focused car body designed via CFD and validated through 3D printed prototyping. An automotive component engineering project built from a fiberglass and carbon fiber weave for a lightweight 40kg chassis.
Challenge
The engineering problem was an equation of constraints: design a minimalist, performance-focused car body to fit a pre-existing mechanical layout. The goal was a union of aesthetics and function. We took the client's initial wave of concepts and drawings, exploring forms that were shown in clay and paper. From this array of possibilities, a core design direction was selected.
Solution
A design is not valid until it is tested. We conducted aerodynamic CFD analysis to refine the surface geometry, a process that identified and corrected a 15% drag inefficiency in the headlight design. In parallel, small-scale 3D prints were created to provide physical, tangible confirmation of the car’s proportions and visual impact. The simulations and physical models were in agreement; the design was validated.
Result
With a confirmed design, manufacturing was a direct execution of the plan. Full-size body panels were 3D printed, serving as perfect masters for creating the final production molds. From these, the carbon fiber shell was laid up and delivered. The result was a lightweight, rigid, and aerodynamically optimized body that integrated flawlessly with the client's build.