Aerodynamics Engineer

Spire Holdings, LLC. and affiliated companies-posted about 2 months ago
Mooresville, NC
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The Aerodynamics Engineer is responsible for the end-to-end development, analysis, and correlation of aerodynamic concepts and components to improve vehicle performance across all racing applications. This role combines simulation, experimental testing, and race data correlation to ensure that aerodynamic upgrades translate to measurable, repeatable on-track performance. The position requires a high degree of technical expertise, collaboration across design and manufacturing functions, and the ability to manage multiple development streams under tight competitive timelines.

  • Develop aerodynamic concepts, surfaces, and assemblies using CAD and CFD tools to improve downforce, balance, and efficiency.
  • Perform detailed CFD studies including mesh setup, solver execution, and post-processing to evaluate aerodynamic loads, flow structures, and sensitivity to ride height, yaw, and steer.
  • Lead the design loop from CFD to CAD release, coordinating with Design and Composites to ensure aerodynamic intent is achieved in final manufactured parts.
  • Generate and maintain aero maps and sensitivity plots for each vehicle configuration to inform setup optimization and race strategy.
  • Identify and prioritize aerodynamic development areas based on performance modeling, competitor benchmarking, and regulatory changes.
  • Plan, coordinate, and execute wind tunnel programs including model preparation, instrumentation, calibration, and test matrix development.
  • Analyze wind tunnel data, generate performance summaries, and correlate findings with CFD and track data.
  • Support hardware instrumentation for aero testing, including pressure taps, flow visualization, and load cell measurement systems.
  • Manage part flow, logistics, and configuration tracking for all tunnel tests.
  • Work directly with vehicle performance, simulation, and race engineering groups to correlate CFD and wind tunnel predictions with real-world telemetry and race data.
  • Analyze track test and race event data to validate aero models, identify performance gaps, and recommend setup adjustments.
  • Provide pre-event and post-event aerodynamic performance reports including drag/downforce balance, ride height sensitivities, and trim efficiency.
  • Develop and maintain automation tools for CFD batch processing, post-processing, and aero map generation (Python, MATLAB, etc.).
  • Implement version control, configuration management, and documentation standards for aerodynamic projects.
  • Support development of digital workflows connecting CFD, CAD, and PLM systems to streamline update cycles and data integrity.
  • Work closely with race engineers, vehicle dynamics engineers, and design staff to translate aerodynamic insights into actionable vehicle setup or component recommendations.
  • Engage with suppliers and series partners to ensure compliance with aerodynamic regulations and technical bulletins.
  • Participate in the competitive development cycle by tracking rule updates, homologation windows, and competitor design trends.
  • Contribute to long-term aero development planning and technology roadmaps.
  • Study and analyze competitor trends to understand methodologies.
  • Other duties as assigned
  • Bachelor’s degree in Aerospace Engineering, Mechanical Engineering, or related field required.
  • 3–7+ years of experience in motorsport, high-performance automotive, or aerospace aerodynamic development.
  • Proven expertise in CFD analysis using STAR-CCM+, ANSYS Fluent, OpenFOAM, or equivalent.
  • Strong CAD skills (Siemens NX, CATIA, SolidWorks) and understanding of design-for-manufacture principles.
  • Hands-on experience in wind tunnel testing and data reduction.
  • Knowledge of race vehicle dynamics, flow visualization techniques, and aero correlation processes.
  • Master’s degree in Aerodynamics or Computational Fluid Dynamics preferred.
  • Experience with Python, MATLAB, or other scripting tools for data analysis and automation preferred.
  • Prior experience in NASCAR, IndyCar, IMSA, or other professional motorsport environments highly desirable.
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