CFD-optimized E3D F1 Buggy (with ground effect!)

Who said buggies can't go fast? 

This version of the #E3DBuggy features a complete aerodynamic package that was validated with CFD simulations: welcome the #E3D4F1!

The goal of this project was to keep the original nature of the Buggy as a comprehensive test, while introducing more people to the fascinating world of aerodynamics. The part is therefore fully printable - you will learn a lot about bridging! - with the sole exception of the front wing's main-plane that needs supports. Feel free to drop a comment and ask for clarifications regarding any aerodynamic feature: every added piece has a purpose!

Aerodynamic features:

• Front wing: multi-element wing made of main-plane + 2 flaps. The 2 flaps and their internal endplate are shaped to generate a very effective outwash effect that helps direct the airflow outside the front wheels, reducing their drag. The central section of the main-plane has a neutral AoA (angle of attack) in order to mitigate the disturbance to the diffuser inlet, whereas the outer section returns to a higher AoA to produce downforce. Unfortunately this is the reason why the front wing isn't a bridge and needs local supports, but hey, aero is well worth some sacrifice ;)
• Diffuser: shaped around an internal airfoil - would never erase the logo of the sponsor for the sake of a few more downforce points - it expands the air both in XY and Z directions to maximize suction at the centerline of the car, hence downforce. Would surely benefit from an increase in ride height if only my SolidWorks wouldn't crash when I try to edit the parameter.
• Rear wing: multi-element wing made of main-plane + flap. Features lateral slots for local increase in downforce (and fancy generation of counter-rotating vortices) and a gurney flap at the trailing edge of the flap for an efficient additional amount of downforce.
• Beam wing: single-element wing that was meant to only help the rear wing by cleaning up the flow directed to the rear, but actually ended up producing way more downforce. This is because the rear wing sees a very dirty airflow coming from the front bumper that loses most of its energy in the detachment.
• Roof: features a small downwashing flap that, although it generates a small amount of local lift, helps containing the wake of the Union Jack. At the back, a transversal slot is cut through the roof to bleed some of the high pressure that builds up under the roof (which generates an absurd amount of lift).
• Roof pillars: shaped as symmetric airfoils with the double goal of minimizing drag and disturbance to the rear wing.

Printing profile:

• Experiment with your bridging-specific settings. Except for the front wing, the entirety of the print does not rely on supports but exploits bridging.
• Print preferably with a layer height < 0.20 mm to enhance details. Can also scale the print > 100% if you feel like using a bit more material - the aero package is worth it!
• The thin endplates of front wing and diffuser will stress test your bed adhesion, since they're only 1 line thick. If you can't avoid lifting, don't worry and use a brim with 0.2-0.3 mm distance from the print.

Have fun and happy racing!