OpenRC F1 Advanced Aero Package

Hello!
After more than a year of using great, OpenRC F1 designed by Daniel Noree, we decided to take on the challenge of designing a working aerodynamic package for the project, and here it is!

AERODYNAMICS & PERFORMANCE
It's a package of working ground effect floor with sideskirts, diffuser and the rear wing having a working profile of both airfoils. It was tested in various car and pavement configurations. Also in the gallery, you can see the CFD simulations we conducted.
It literally sucks the car in when driving at high
speeds, what significantly improves stability at high speeds.
It was designed for Tamiya F104 tires, with limited test space, managed to establish a Vmax of 70kmh, which was achieved thanks to the stability generated by the downforce and very significantly eliminated the problem of spinning in corners. (Vmax could have been higher if we had found a longer test area).

BIGGER SERVO
We also designed the mount for a much larger and more powerful servo, which has more durability and does not get tired at high speeds.

NEW FRONT WING
According to user requests, as an update to the project we decided to design a realistic front wing. It features individual wings with gaps between each wing, as is the case in real F1 cars, in order not to stall the entire downforce-generating surface.
It is optimized as much as possible for printing, however, we note that it is especially recommended to have a well-calibrated printer and non-moist, good-quality PET-G. Wanting to keep the shape as realistic as possible, the wing has a smaller cross section than the original project wing. For this reason, it is required to use a "crash safe" solution link.

Consider that floors that generate aerodynamic downforce must be suspended as low as possible above the surface. For this reason, the floor in our design has a clearance of about 5mm, small pebbles are not a problem, but we recommend driving on paved/asphalted areas.

Videos of the rides: link

BOM:

M2
- 10x Cup head screw 5/6mm

M3
- 4x nuts
- 2x Countersunk screws 8mm
- 2x Button head 14mm
- 3x Button head 5mm
Front Wing: 
- 2x Countersunk screws 6mm
- 2x nuts

Bigger servo:
- 17G, we used link

Our Q&A is available on the OpenRC Facebook group: link

3D PRINTING SETTINGS

FLEX
Floor_Plug - 100% infill
Sideskirts - (ninja flex or 40d give best result) 100% infill, layer 0.2
Diffuser - (VERY hard TPU 96A, you can print it with PETG, but we do not guarantee long life of that part), 100% infill, layer 0.2
(optionally) - Wheel_Axle_Holders (VERY hard TPU 96A), 60% infill, layer 0.2

PLA
Rear_Wing - 100% infill or many perimeters, supports on buildplate, layer 0.2/0.15
Servo_Holder - 40% infill layer 0.2
Diffuser_Cover - 100% infill, supports, filament change on specific layer, layer 0.1
Diffuser_Cover_For_LED - (transparent) 100% infill, no support, layer 0.1
Floor_Vanes supports - 100% infill, layer 0.1

PETG
Chassie_rear - 4 perimeters, 40% infill, min 6 solid top layers, layer 0.2 (you can lower layer height in PrusaSlicer for a height of 4.20mm to 9mm for greater smoothness)
Chassie_Front - same as Chassie Rear
Wheel_Axle_Holders - 60% infill, layer 0.2

If you want to get rounded floor vanes front you can print them from the Floor_Vanes_printable_horrizontaly file with supports, but they are very difficult to print if your printer has poor cooling.