Build area 2 - ACTIVATE

Build Area Highlight: Body Design & Components – TRANSFORM

This is one of the coolest episodes of the series, this is where iron man tony stark meets automotive, taking mechatronics to a whole new level, as a brand build partner , your role is to work with the team developing the body work and aero parts to ensure your job is  a lot easier, your role will be electronics and mechanisms , the electronics controller needs to work with our electronics team at ZENVO , this means the components can be adjusted at anytime and code language is understood by all parties including the kill all metal team.

​

our main end goal is to have a system driven by sensors and Ai that automatically adjusts as well as have settings / modes that are ready to carry out the tasks set below, ideally the components are able to be purchased by the public and can be replicated by the public, but keeping the expert knowledge restricted to your team. Every area of  the build needs to have transferable knowledge to ensure audiences tune in 

​

The cosmetics are not only to be extremely desirable and modern but also be transformative, the idea is to a have a vehicle that transforms - think of the new ford latest GT40 and Mercedes AMG one, but taken to a whole new level, aero comes out further and become more aggressive with a push of a button, or Ai computer learning management. 

​

Aero Parts that are being manufactured by build partner 1 but have consultations of you our build partner 2.

A Pikes Peak car is designed for extreme performance on one of the most challenging hill climbs in the world. The goal is to achieve maximum downforce, optimal airflow management, and lightweight durability to handle the high altitude and tight corners. Below is a list of aero parts required for this build:

Carbon Fibre Body Panels (Base Conversion)

• Roof Panel – Replace with carbon fibre for weight reduction and a lower center of gravity.

• Doors – Lightweight carbon fibre doors to reduce weight while maintaining durability.

• Bonnet (Hood) – Carbon fibre with integrated vents to release engine heat.

• Boot Lid (Trunk) – Carbon fibre to reduce rear weight and maintain balance.

• Wing Mirrors – Aerodynamically designed carbon fibre mirrors to reduce drag.

Custom Aerodynamic Components

1. Wide Arches (Fender Flares)

   • Wider arches to accommodate larger, high-performance tyres and improve stability.

   • Designed to channel airflow smoothly around the wheels.

2. Front Bumper with Integrated Aero

   • Aggressive carbon fibre front bumper with air intakes for cooling brakes and drivetrain components.

   • Optimized for minimal drag and maximum airflow efficiency.

3. Side Skirts

   • Carbon fibre side skirts to prevent air from flowing underneath the car, improving stability and downforce.

4. Rear Bumper with Diffuser Integration

   • Aerodynamic carbon fibre rear bumper with a large rear diffuser to optimize airflow and reduce turbulence at the rear.

5. Rear Diffuser

   • High-efficiency carbon fibre diffuser to increase downforce by accelerating air exiting under the car.

6. Front Splitter

   • Large carbon fibre splitter to generate significant downforce at the front and improve cornering grip.

7. Canards (Dive Planes)

   • Carbon fibre canards on the front bumper to direct air to key areas and enhance front-end downforce.

8. Active Rear Wing

   • Fully adjustable carbon fibre rear wing with active aero capabilities, allowing for:

     • Increased downforce during corners and braking.

     • Reduced drag on straights for higher top speeds.

 

Cooling and Pressure Management

1. Vented Bonnet (Hood)

   • Integrated vents to release engine heat and improve airflow over the car.

2. Brake Cooling Ducts

   • Ducts integrated into the front bumper and side arches to direct cool air to the brakes, preventing overheating.

3. Roof Scoop (Optional)

   • Roof-mounted scoop for additional cooling to key components such as the drivetrain or batteries (if EV).

4. Pressure-Release Vents

   • Located on the front and rear arches to release built-up air pressure from the wheel wells.

 

Additional Components

1. Wheel Covers

   • Aerodynamic wheel covers to reduce drag and improve airflow around the wheels.

2. Underbody Panels

   • Full carbon fibre underbody panels to create a smooth surface underneath the car, reducing drag and increasing under-car airflow efficiency.

3. Side Vortex Generators

   • Small aero devices near the rear pillars to manage airflow over the sides of the car, improving stability and downforce.

4. Rear Wing Endplates

   • Large vertical plates on the sides of the rear wing to reduce wingtip vortices and improve aerodynamic efficiency.

5. Front Dive Planes (Underbody Aero)

   • Additional devices under the front splitter to manage airflow beneath the car.

 

3D Design and Integration

• The 3D scanned model of the original car serves as the base for designing and fitting all the new aero components.

• Digital wind tunnel simulations will be used to optimize the performance of the aero parts before production.

• Components will be designed in STEP files for mould and manufacturing processes.

 

Performance Goals

• Downforce: Maximize stability through tight corners and steep inclines.

• Cooling: Ensure optimal temperature control for high-altitude operation.

• Weight Reduction: Minimize weight with carbon fibre components to counteract power loss at altitude.

• Adaptability: Allow active aero systems to dynamically adjust for straights, corners, and braking zones.

This comprehensive aero package ensures the hot hatch is capable of competing at the highest level at Pikes Peak, combining cutting-edge performance, innovation, and design.

 

What You’ll Be Working On

​

1. 3D Model Integration:

   • Our cast members will provide a complete 3D scan of the standard vehicle, inside and out.

   • Combined with renderings created by Musa Tahoo of West Coast Customs, your task is to turn these designs into fully functional body components.

2. Component Design:

   • Create workable STEP files for both moulds and components, ensuring precision and manufacturability.

   • Leverage cutting-edge materials such as Carbotanium or other space-travel-grade composites for lightweight strength.

3. Aerodynamic Excellence:

   • Collaborate with your team or external partners like SolidWorks/Dassault Systems and AWS to refine the aerodynamics. Every curve and edge should optimize performance.

4. Material Innovation & Manufacturing:

   • Utilize digital sheet forming for mould creation and CMM measuring to ensure precision and consistency.

   • Incorporate advanced manufacturing processes that demonstrate the future of engineering and push the boundaries of material science.

Your Deliverables

1. Digital Design & Educational Content:

   • Provide engaging digital content from your design team, showcasing the creative and technical processes behind your work.

   • Deliver educational data tailored to materials, specifications, and manufacturing techniques, helping to inspire and educate the next generation.

2. Manufacturing Insights:

   • Share exciting manufacturing processes that highlight innovation in materials, moulding, and production.

   • Showcase the cutting-edge techniques that make your brand a leader in automotive engineering.

3. Workable Files:

   • Supply ready-to-use STEP files for moulds and components, ensuring seamless integration into the build process.

Why This Role Matters

• Showcase Your Expertise: As a key contributor, your work on the Aerodynamic mechanism design will set the stage for the vehicle’s identity, performance, and innovation.

• Inspire the Next Generation: The data and educational materials you provide will be shared worldwide through the Ultra E app, helping to inspire students and professionals alike.

• Global Exposure: Your contributions will be prominently featured across Amazon Prime, YouTube, and social media, providing unmatched visibility for your brand.

The Opportunity

By taking on this build area, you’re positioning your brand as a leader in automotive innovation and education. From advanced materials to cutting-edge aerodynamics, your involvement will help redefine what’s possible in engineering while leaving a lasting impact on the industry. Join us in creating history and inspiring the engineers of tomorrow.

​

​