The Revozport Aero Development Process - From Digital Scan to Downforce

At Revozport, every aerodynamic package starts with precision data. We pair full-vehicle digitization with advanced simulation and real-world validation to deliver dry-carbon kits that look fast and work even better on track.

1 — Full-Vehicle Digitization

The process begins by 3D scanning the entire car: exterior surfaces, wheel wells, underbody, engine bay, cooling stack, every surface that influences airflow. This scan data forms the foundation of our development, giving us a high-fidelity reference model that ensures perfect fitment, accurate geometry, and proper packaging for serviceability and performance.

2 — From Scan to Engineering Model

Raw scans are refined into clean, engineering-grade CAD models. We define datum points, tire growth envelopes, rake parameters, and keep-out zones for suspension travel, steering angle, and brake ducts. This guarantees each component is engineered to OEM-level tolerances and is built to withstand real-world race conditions.

3 — Baseline Aerodynamic Assessment

Before designing new parts, we first understand the stock car’s aerodynamic behavior. Using Computational Fluid Dynamics (CFD), we run steady-state RANS simulations guided by proven motorsport practices. We use the k-ω SST turbulence model and blend wall functions with direct boundary-layer resolution where appropriate. Tires are modeled as smooth rotating walls, and wheels use a Moving Reference Frame (MRF) to accurately simulate rotation even in steady-state analysis.
Cooling flow through radiators is represented with porous media models (Darcy–Forchheimer formulation) to simulate realistic pressure loss through the heat exchangers. Each simulation includes both straight-ahead and yawed conditions to study stability in crosswinds.

4 — Concept Development & CFD Iteration

Armed with a clear baseline, we develop and test aerodynamic concepts such as splitters, canards, side skirts, diffusers, and rear wings. Each concept is refined through iterative CFD studies, where changes are quantified in drag, downforce, and balance. We evaluate total system behavior including how front and rear components interact as a package, rather than in isolation. This ensures consistency across varying speeds and ride heights. Components are optimized to work together, producing efficiency and balance as one integrated system.

 5 — Higher-Fidelity Simulation

Once promising configurations emerge, we apply hybrid LES methods, such as DDES (Delayed Detached Eddy Simulation), to model unsteady flow separation and wake dynamics more accurately. This time-domain simulation predicts real-world aerodynamic behavior, especially on geometries prone to separate like diffusers and wings, far beyond what standard RANS can achieve.

6 — Setting System-Level Targets

Our goal is not just maximum downforce, but usable downforce & aerodynamic balance changes across the full ride height window. We analyze CzA (downforce coefficient × frontal area), CxA (downforce coefficient x frontal area), ride height sensitivity, and aero balance shifts with wing angle to develop tuning windows for each kit. These metrics guide the ideal balance point for different circuits and driver preferences.

7 — Prototype Fabrication & Track Validation

Validated designs are brought into prototype production using rapid CNC machining, autoclave tooling, and pre-preg carbon layups. Test fitment and on-track evaluation follow.  We record damper travel, ride height, and speed-to-downforce correlation using calibrated sensors and data loggers on some packages. The results are used to validate or correlate CFD findings and inform final recommendations for setup, wing angles, and rake tuning.

8 — Production in Dry Carbon Fiber

Every production component is made from pre-preg autoclave carbon fiber (dry), following strict ply-book documentation. The result is exceptional stiffness, minimal weight, and world-class finish. Our quality control ensures every piece meets the same dimensional accuracy as our prototypes—so what you buy is exactly what we tested.

9 —Customer Support

Every kit is supplied with detailed install guides and hardware. Revozport supports its customer base with technical documentation, and CFD-based performance data to help you understand the full story and design of the product.

Why It Works

• Quantified results: Every change is compared to the OEM baseline for measurable gains.
• Integrated system: All elements: splitter, skirts, diffuser, and wing are designed as one cohesive aerodynamic system.
• CFD-to-track correlation: Data-backed development ensures predicted gains match real-world performance.
• Dry-carbon construction: Lightweight, strong, and built to perform under extreme track conditions.

The Result

From first scan to final autoclave cure, Revozport’s aerodynamic process ensures every design is functional, tested, and track-proven. It’s not just carbon fiber; it’s engineered jaw dropping performance.