Vehicle Design and Aerodynamics Project¶

Abstract¶

This is a hands-on, project-based course that guides you through the process of creating a customized 3D car model using AI tools, refining it in Nomad Sculpt, 3D printing it, and transforming it into a fully functional 4WD remote-controlled (RC) vehicle. The course combines creative design, digital modeling, physical prototyping, and basic electronics.

What You Will Learn¶

How to use AI tools to generate 3D models of vehicles
Techniques to import, clean, and refine models using Nomad Sculpt
Customization of car components like bumpers, skirts, spoilers, etc.
Preparing and slicing models for 3D printing
Basics of 3D printing and post-processing techniques
How to assemble and wire an RC 4WD chassis
Presenting and testing your final product

What You Will Need¶

Category	Item	Notes	Required/Optional
Hardware	Smartphone/Tablet	With stylus support recommended	Required
	Laptop/Desktop	For slicing and 3D printing	Required
	FDM 3D Printer	e.g. BambuLab	Required
	Resin 3D Printer	for better finishing e.g. Phrozen	Optional
	RC Car 4WD Chassis Kit	Chassis for the car model	Required
Software	AI Model Generation	ChatGPT, Tripo AI	Required
	Nomad Sculpt	iOS/Android – paid	Required
	Nomad Sculpt Quad Remesh extention	iOS/Android – paid	Optional
	Slicing Software	Chitubox, Bambu Studio	Required
Tools & Materials	3D Printer Filament	PLA or PETG recommended	Required
	Finishing Tools	Sandpaper or rotary tool	Optional
	Painting tools	Brushes, acrylic, Airbrush or spray paint	Optional
	RC Control System	Beets motor unit	Required
	Assembly Hardware	Screws, brackets, and mounting accessories	Required

Course Outline¶

Chapter 1: Introduction to AI-Driven Design¶

Overview of AI 3D generation tools
Limitations of AI generated 3D models
Exploring car design prompts and outputs
Generate a car model image using ChatGPT
Use the images to generate 3D models using Tripo AI

Chapter 2: Sculpting Foundations in Nomad Sculpt¶

Introduction to sculpting interface
Importing and repairing AI-generated models
Cleaning geometry and optimizing meshes
Refining car body shape and proportions

Chapter 3: Customizing the Car¶

Adding car skirts, bumpers, fenders, spoilers, etc.
Feedback sessions on design choices
Exporting final car body for print

Chapter 4: 3D Printing¶

Introduction of different 3D printing methods
Exporting STL files and configuring printer settings
Model slicing basics: orientation, supports, infill
Slice and preview print in Bambu Studio
Operate a 3D printer and print

Chapter 5: Post-Processing and assembly¶

Sanding the printed model
painting the car body
Various post-processing techniques

Chapter 6: testing¶

Understanding and installing key RC components (Motor, servo, wheels)
Mounting the body securely on the chassis
Testing and calibrating your RC car for performance

Project Steps¶

1. Generating the 3D Model¶

Objective: Create an initial 3D car model using AI tools.

Content: 1. Learn and practice AI prompts and generate a blank car model using ChatGPT 2. Use Tripo AI to generate a 3D model: - Upload your reference image - Adjust generation parameters as needed - Download the generated 3D model

Generate car image using ChatGPT Use the image to generate a car 3D model using Tripo AI

2. Model Modification¶

Objective: Customize the car model's appearance.

Content: 1. Import the generated model into Nomad Sculpt 2. Remesh the model(Preferrably Quad Remesh Tool) 3. Learn about basic car customisation options 4. Use basic modification tools: - Masking tool for maintaining certain parts - Move and Drag tool for reshaping windshield and overall shape - Clay for skirts, fender and smooth it - Clay, move and smooth for front bumper and rear bumper - Use Primitives and trim tool for spoilers - Smooth tool for evening out rough spots

Car model in Nomad before directly imported from Tripo AI Reference for what car parts can be customised

Example of car model after modification

3. Preparing for 3D Printing¶

Objective: Export the 3D model for printing.

Content: 1. Export model from Nomad in STL format 2. Import into slicer software: - Adjust model orientation for optimal printing - Add support structures - Configure print settings (layer height, infill, etc.) 3. Generate G-code and print

Slicer Setup (Bambu Studio)

3D print preview

4. Post-processing, assembly and test running¶

Remove support structures
sand the surfaces and support structure marks
Assemble the car cover onto the Chassis and Beets motor unit

Optional Projects¶

3D scanning¶

3D scanning can be used instead of AI model generation. Students can experience the process of scanning real life toy cars and import them into Nomad.
Scanned models takes more time and proficiency to fix so this is not recommended for first timers.
3D scanner is required

Wind Tunnel Testing¶

Learn about the basic aerodynamic principles and the usage of a wind tunnel
Test different car designs for aerodynamic efficiency
Observe the behaviour of Streamlines and compare them for different student designs
Document results and make design improvements
This is mainly aimed towards Physics/Engineering related students
Desktop wind tunnel is required

Note: Images shown are placeholders. Replace with actual project photos.