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CASE STUDY
Turning aerodynamic performance into design insight with AOX
2026. 04. 20
AOX turns sensitivity maps into design direction
If CFD shows how the current shape performs, AOX helps answer which surfaces to change next and turns that direction into shape candidates designers and engineers can review together.
Input
Choose editable and protected regions
Split regions with STL patches or use brush selection directly on the geometry.
Adjoint CFD
Read the clues in the airflow
Adjoint CFD computes sensitivity maps for objectives such as drag or downforce, showing which surfaces can change performance.
Shape Optimization
Turn clues into the next shape candidate
FFD-style workflows often reduce problem size around control points. AOX takes a different approach, keeping many local surface rules while computing shape updates without explicitly storing a large constraint matrix.
Geometry I/O
Ingest raw STLs, select editable and protected patches, then map the final surface displacement back to the original STL to return optimized STLs.
Shape Model
Represents editable surfaces as small change units and applies regularization and smooth transitions so sensitivity signals do not directly become rough geometry.
Adjoint CFD
Evaluates the current aerodynamic performance, then computes surface directions worth exploring through sensitivity maps for drag or downforce objectives.
Optimization
Computes the next shape update while preserving design rules such as fixed mounting areas, movement limits, and keep-out spaces around nearby parts.
Mesh deformation
Propagates the computed surface change into the volume mesh with p-Laplacian-based deformation, using remesh only when mesh quality breaks down.
From setup to optimized STL
AOX connects region selection, objective setup, CFD/Adjoint computation, shape update, mesh deformation, and STL output into one repeatable pipeline.
In simple terms
The user defines which surfaces can change and which must stay fixed. AOX then repeats the process from CFD/Adjoint computation to shape update, mesh deformation, and optimized STL output. The result is not just a sensitivity map, but the next shape candidate ready for design review.
0
STL input
Import the design geometry as STL patches.
1
Patch selection
Separate editable and protected regions.
2
Shape setup
Define surface change units, smoothing behavior, and design rules.
3
Mesh generation
Generate the simulation mesh.
4
Flow evaluation
Evaluate current aerodynamic performance and objective values.
5
Adjoint CFD
Compute drag/downforce sensitivity maps.
6
Shape optimization
Compute the update using both sensitivity and design rules.
7
Forward regularization
Convert rough change signals into smooth surface changes.
8
Mesh deformation
Propagate surface changes into the volume mesh with p-Laplacian. Remesh when needed.
9
Optimized STL
Return a review-ready shape candidate.
A shape must be buildable, not just good-looking
Mounting areas, sealing surfaces, and connection regions can be fixed, while only editable surfaces become targets for shape update. AOX does not apply sensitivity maps directly; it computes the next candidate within design rules that support manufacturing and review.
Simulation must continue as the shape changes
AOX avoids restarting from scratch after every surface change. Instead, p-Laplacian-based mesh deformation helps the volume mesh follow the change. Remeshing is used only when mesh quality breaks down, keeping the simulation loop moving.
Refining the existing shape, not generating random forms
AOX is not topology optimization that creates holes or separates surfaces. It is closer to shape refinement: keeping the existing design structure while adjusting surfaces based on aerodynamic clues.
Connecting CFD results to design decisions
AOX is not a replacement for high-fidelity CFD. Its role is to turn performance information from CFD into direction and shape candidates that help designers decide what to try next.
Item
Typical CFD-centered workflow
What AOX adds
Role
Analyzes how the current shape performs and shows problem areas.
Connects sensitivity maps and shape updates to suggest which surfaces to change next.
Design rules
Often requires separate adjustment or manual cleanup after simulation.
Considers fixed regions, movement limits, and keep-out spaces directly within the shape update.
Difference from FFD
FFD-style workflows usually reduce problem size around control points when computing shape updates.
AOX keeps many local surface rules while computing shape updates without explicitly storing a large constraint matrix.
Output
Primarily performance direction or flow analysis results.
Returns smooth candidate geometry and optimized STL that can be reviewed in a design process.
User experience
Closer to a workflow configured and interpreted by CFD specialists.
Lets designers and engineers make decisions from the same sensitivity maps and candidate shapes.