Development of bodywork for Danish Thunder Championship

  • DTC Race
  • 2 racecars | DAVINCI 3D
  • Mercedes | DAVINCI 3D
  • Racecar - Mercedes | DAVINCI 3D
  • sponsered car | DAVINCI 3D

DAVINCI develops Audi and Mercedes bodywork to DTC

Phase 1 – 3D Scanning

DAVINCI development A/S has entered Danish motorsport, where we have entered into collaboration with the Danish Thundersport Championship, for the development of bodywork for the motorsport series, based on high-end sports coupes. The development is centered around an Audi RS5 and a Mercedes AMG C63. In addition, a 3D scan of a current DTC racecar, a Chevrolet Camaro, has been carried out. Our partner is Zebicon, who has carried out the scans. Read more about phase 1 of the DTC project


Audi RS5 in the process of being 3D scanned.


Tubular frame mounted, prepared for 3D scan.

Phase 2  – Modeling of the bodywork

In this part of the project, the focus of attention is on adjusting the scanned data, so that the final result will still resemble the original. The models must be 150 millimeters lower and the wheelbase has to be about 100 millimeters shorter, whereas the front’s appearance has to be 1:1. Read more about modeling of the bodywork


Scan the original DTC race car


Modelling of Mercedes scanning.

Phase 3 – Flow simulation of bodywork

The race organizers want to make sure that using a specific bodywork can’t be an advantage for the teams. To ensure this, the Camaro, Audi and Mercedes are subjected to CFD analysis. CFD stands for Computational Fluid Dynamics, which is a general term for software that can simulate the flow of gases or fluids through a tube or around an object. Air is a combination of different gases and vapors, which is well-defined in most CFD software. Read more about Flow simulation of bodywork

Merzedes Flow simuleres i CFD software

Mercedes in Flow Simulation

Audi Flow simuleres i CFD software

Audi in Flow Simulation

Phase 4 –  Production base

Together with the customer, it was decided that the chassis of each car would be split into 14 parts. This was done with regards to the manufacturing process, and the possibility to replace exposed parts both during and after a race. To start the process, the design of each chassis is split into 14 parts in the CAD program, NX. Hereafter, a CAD file is created for each part, as the basis for the mold. Flanges for assembling the cars are modeled, and it is examined for sharp edges, as it is an issue when molding fiberglass. The casting mold is modeled based on the particular part, in order for it to be prepared for infusion molding. Read more about the Production base phase

Phase 5  – Production of first series and assembly

In connection to the production of the panels, suppliers and sub-suppliers were visited to ensure a proper understanding of the design decisions and specifications. It turned out that the sub-suppliers had specific requests regarding windows and brackets, concerning e.g. materials, which we were asked to validate before they proceeded. When all parts had been sent to production, there was an opportunity to follow the fitting process of one of the new cars, by visiting a team that had bought one of the bodyworks. Read more about Production og first assembly