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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 bypassed the limitations of human sketching and deployed AI to generate the initial wave of concepts, exploring forms that a conventional process might have missed. From this array of possibilities, a core design direction was selected.
This initial concept, however, was merely a suggestion. We tasked the AI again, this time to synthesize and refine the chosen form, using the packaging constraints as hard limits. The system iterated, hardening the lines and optimizing the shape for structural integrity before a single surface was modeled. This AI-synthesized form became the foundation for the engineering phase in Fusion 360. There, it was translated into mathematically precise class-A surfaces, creating a digital twin ready for analysis and production.
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.
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. As the client, Kuehn Proven, confirmed: "Wow, looks fantastic with the lights and side vents!".
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