CFD & Carbon Fiber — PB Powertrains

Simulation First

Every aero component we ship starts as a simulation. Our in-house CFD workflow covers airfoil profile development, multi-element wing synthesis, and full underbody flow analysis — then we build the part in carbon fiber, in-house, and validate it on track.

Vorticity streamlines over a swan-neck mounted wing — Q-criterion vorticity streamlines, swan-neck mount configuration, shallow angle of attack.

Vorticity streamlines at medium angle of attack — Medium angle of attack — attached suction-side flow and a clean, tight vortex system.

Vorticity streamlines at high angle of attack — High angle of attack — mapping the onset of separation so drivers keep usable downforce past the peak.

From Airfoil to Answer

Profile selection is an optimization problem, not a guess. We blend and screen high-lift airfoil candidates against the target's Reynolds regime, then carry the winner through 2-D polars into full 3-D car cases.

Drag polar comparing a blended airfoil against its reference at Re 100,000 — 2-D drag polar: blended profile vs. reference airfoil at Re = 100,000 — more lift at the same drag bucket.

Simulated downforce versus inlet velocity — Component downforce sweep, 50–150 km/h inlet — the numbers our parts are quoted against.

Carbon Fiber, Built In-House

Two production routes cover both ends of the market: compression molding for high-volume panels, brackets, and surrounds; and autoclave-cured pre-preg for safety-critical structures — monocoque elements, large aerofoils, battery enclosures. Cloth cutting, CNC trimming, and a dedicated paint booth complete the chain from raw fabric to finished part.

Material	Density	Tensile Strength	Specific Strength	Notes
CFRP	1.6–1.8 g/cm³	3,000+ MPa	20× steel · 15× aluminum	Corrosion-proof, near-zero thermal expansion
6061-T6 Aluminum	2.7 g/cm³	~310 MPa	Good	The default lightweight metal
High-Strength Steel	7.85 g/cm³	550–700 MPa	Limited by self-weight	Cheap, mature, heavy

Autoclave-cured carbon-fiber GT wing — Autoclave-cured GT wing — the process behind our safety-critical aero structures.

Forged-carbon hood panel — one-piece molding for large body closures.

Carbon-fiber aero kit components — Front lip, side skirt, and diffuser elements — full aero kits to drawing.

Assorted precision carbon-fiber components — Precision trim and functional components, straight off the tooling.

Commission Design & Production →