2-Piece A-Arm Wing

The goal of this project was to create a very simple and light solution to reduce the drag that is formed around A-Arm suspension members. This is achieved by using a screw on each side of the wing shell to clamp onto the A-Arm creating a more aerodynamic profile.

They are designed to be a lightweight shell structure and need to be quickly disassembled.

To create this mold, I will be using my 3D printer to make the male tooling (UPPER PIC). This will allow for easier sanding & finishing. Then I will make a female tool (LOWER PIC) by laminating directly to my 3D print.

I believe this extra tooling step is necessary because this a universal design for all A-Arms on the FSAE car so I will need to make 5 Wings per corner X 4 corners, which equals 20 sets of wings. A fiberglass female mold with tooling gelcoat will withstand more part removals then a 3D printed surface.

The shell halves can clamp to the A-Arm with an undersized center profile. The mounting will be achieved through a rivet nut & Bolt connection. The leading edge must be sealed from air so a undercut tab will be created in the lamination.

I have yet to design a trailing edge sealing system but this may not be necessary if the trailing edge wing skins are cut 0.5-1 mm long and the interference pressure causes a seal.