Motorcycles, Racing and Aerodynamics!
3D Engineering and Aerodynamic Development
The development of motorcycle aerodynamics in racing, has seen a massive increase over the last few years. As speeds continue to rise, reducing drag and enhancing downforce have become essential for improving stability, cornering ability, and acceleration.
Computational fluid dynamics (CFD) facilitates detailed, complex and cost-effective solutions. As a result, more and more teams can now afford to explore custom aerodynamic solutions in the search for improved performance.
Catesby Projects recently assisted a Supersport team in increasing top speed for an upcoming race. We supported the customer from 3D scanning the existing bike geometry, through an aerodynamic development programme using CFD, to manufacturing with our 3D printers.
First 3D Scanning
then Aero Development
As stated, we began by 3D scanning the bike. One area we focused on in particular was capturing the internal details of the engine bay, as the flow paths significantly impact the wakes around the rider.
It was also critical to ensure the rider was scanned in a realistic position. A combination of the rider’s experience, team input, and race images verified positioning before scanning. We were then able to find ways to reduce drag by deflecting wakes around the rider.
Once the geometry was scanned, we conducted an aerodynamic development programme focused on modifications to the windshield, fairing, and radiator ducts, resulting in an 11% drag reduction in CFD simulations.
11%
Drag Reduction
+27%
Radiator Cooling
Mass Flow
From CFD
to the real world
The radiator duct was fully manufactured in-house, using our 3D printing. Careful design ensured the duct allowed fork rotation without compromising the seal, utilising both a fixed panel attached to the fairing and radiators and a sliding panel attached to the forks. Additionally, materials were selected for their heat resistance qualities, weight, and compatibility with 3D printing.
For the fairings and windshield, we created moulds for experts to manufacture the components. We considered manufacturing process requirements, including heat resistance, stiffness, and a smooth finish to ensure the components matched the aerodynamic properties seen in CFD.
