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.

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.

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.

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

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.

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.

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