Engineers quickly understood the advantages of movable aerodynamic surfaces. Just as quickly, championships banned their use to prevent them from monopolizing vehicle development, since this is undoubtedly one of the disciplines that can offer the greatest performance advantage.

Today, more and more car manufacturers are incorporating this technology into their vehicles for two main reasons. The first is to improve aerodynamic efficiency and thus energy consumption. The second—especially in high-performance vehicles—is to generate the right amount of downforce in real time, depending on the driving conditions. In both cases, composites are extremely useful, but in the latter scenario they become essential.

Not only the rear spoiler is active. In this example, the Porsche 911 Turbo S extends or retracts its front spoiler lip depending on the selected driving mode and vehicle speed. Additionally, the cooling air flaps open or close to regulate airflow through the air intakes and reduce drag whenever possible. Credit: Porsche

How do active aerodynamics work?

The system operates through multiple sensors that provide input to a “brain” that processes the information, assesses the vehicle’s current state, and interprets the driver’s intentions. Based on this, it instructs actuators to place the movable aerodynamic surfaces in the optimal position for each circumstance, all in real time and with extremely fast response speeds—several times per second.

Each design is different, but the rear wings of some hypercars can be subjected to extremely high aerodynamic loads at high speeds, which demands an extremely robust structure. At the same time, hypercars pursue the lowest possible weight to optimize performance. High strength and low weight? You can see where this is going.

Why composites for active aerdynamics?

Composites are ideal for constructing active aerodynamic elements. They can be shaped into almost any form while adding as little weight as possible—an especially critical factor for components like rear wings, which are positioned high and far from the car’s center of mass.

Another benefit of their low weight is that the support structures and pivoting joints that allow these components to change position can also be made lighter, reducing the overall weight of the mechanism. Additionally, if the moving parts are lighter, the actuators required to move them can also be lighter and more energy-efficient, again reducing the system’s weight and the power that needs to be drawn from the engine—regardless of its type.

The track oriented Zenvo TSR-S rear spoiler can adapt its lateral angle of attack by up to 20 degrees to optimize the performance also when cornering. Credit: Zenvo

The excellent strength-to-weight ratio of some composites, such as carbon fiber, also allows movable surfaces to change position more quickly. This means they can adapt to the vehicle’s dynamic behavior in real time and provide more effective assistance to the driver at all times.

Composites are the preferred material for building active aerodynamic components due to their unbeatable strength-to-weight ratio. They not only provide outstanding mechanical strength at high speeds, but do so while adding minimal weight—making their implementation more than worthwhile.

The latest trend in movable aerodynamic components is the use of flexible carbon fiber body panels that can change the vehicle’s shape according to the desired aerodynamic profile at any given time. This approach helps eliminate panel gaps, reduces aerodynamically exposed support structures, and even integrates entire elements such as the rear spoiler directly into the vehicle’s body. This results in a better drag-to-downforce balance and, ultimately, improved performance and efficiency.

New composite technology allows the McLaren Speedtail to have integrated ailerons that flex, reducing gaps and therefore aerodynamic disturbance. Credit: McLaren

In short, active aerodynamics are playing an increasingly important role in vehicles—whether to boost performance or improve energy efficiency. Composite materials have proven to be ideal partners for this technology, so it’s likely we’ll see even more movable aerodynamic elements made from composites in the future.

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Horacio understood the high potential of composite-material-based systems and, in particular, carbon fiber while making the Countach Evoluzione at Lamborghini. He tried to persuade Lamborghini to buy an autoclave so they could extend the production of the carbon parts. They refused, saying that Ferrari did not have an autoclave, so Lamborghini didn’t need one.

He then borrowed capital to buy his own autoclave late in 1987 and then, in 1991, he broke away from the company and founded his own consultancy called Modena Design which started to make carbon fiber composites for Formula One cars and clients like Daimler and Ferrari. A couple of years later, he founded Pagani Automobili.

The result couldn’t be any different: The pulsating heart of Pagani craftsmanship is enshrined within one of its signature features and is the first thing that strikes you when you see a Zonda or a Huayra: the carbon fiber front hood with its herringbone weave pattern, a symbol not only of technical research but also a quest for aesthetics!

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