Stellantis Invests $29 5M in Advanced Wind Tunnel Tech to Boost EV Aerodynamics

Stellantis has made a significant investment of $29.5 million to upgrade its wind tunnel at the Auburn Hills, Michigan research and technical center. This innovative project focuses on enhancing the aerodynamics of electric vehicles through a groundbreaking Moving Ground Plane (MGP) technology. By simulating real-world driving conditions, Stellantis aims to improve electric vehicle efficiency, which directly impacts range and battery optimization.

Aerodynamic drag, especially from wheels and tires, plays a critical role in the overall efficiency of vehicles. In fact, up to 10 percent of total aerodynamic drag can come from the wheels alone. By refining this aspect, Stellantis hopes to significantly increase the driving range of their electric vehicles. This, in turn, could lead to smaller battery sizes, cutting costs, and reducing weight—a win-win for both the company and customers. The move is all part of Stellantis’ commitment to advancing cleaner, more sustainable transportation.

Mark Champine, Senior Vice President and Head of North America Engineering Technical Centers, emphasized the importance of this investment. He noted, “Range is a core consideration for customers transitioning to cleaner mobility through battery power.” Reducing aerodynamic drag enhances electric vehicle range and overall performance, making the driving experience more enjoyable for the customer.

The wind tunnel upgrade incorporates advanced MGP technology, allowing for more precise aerodynamic testing. This state-of-the-art system keeps the test vehicles stationary while creating real-world travel conditions. Special belts, suspended by air cushions, allow wheel movement at all four corners of the vehicle, and a fifth belt runs underneath, replicating the car’s actual movement on the road. This setup allows engineers to study and optimize airflow in a realistic setting, giving them the data needed to improve vehicle design and efficiency.

By reducing drag and optimizing aerodynamics, Stellantis aims to increase the driving range of electric vehicles. This not only helps extend battery life, but it can also reduce the size of the batteries needed. Smaller batteries mean less weight and lower costs, making electric vehicles more affordable and sustainable. Champine further explained, “For electric vehicles, improving aerodynamics can lead to potential battery-size reductions, which benefits customers through cost savings and better efficiency.”

Stellantis’ investment in MGP technology is designed to benefit all of its brands, regardless of where the vehicles are sold or what powers them. From compact cars to larger trucks, the technology will provide aerodynamic optimization for a wide range of platforms, including the STLA Large and STLA Frame platforms. Additionally, the wind tunnel upgrade is not just about improving aerodynamics—it also boosts the company’s virtual development tools by providing real-time data that can complement computer simulations.

The Auburn Hills facility now features automation capabilities that were not available before. Changes to vehicle configurations, like adjusting the wheelbase or track width, can be made in just minutes compared to the two hours these modifications used to take. The result? Stellantis can bring new products to market faster, thanks to this streamlined process.

This upgraded facility is a key part of Stellantis’ broader strategy outlined in its Dare Forward 2030 plan. The company aims for 50 percent of its United States sales and 100 percent of its European sales to be battery electric vehicles by 2030, with over 75 battery electric vehicle models available globally by that time. As part of its long-term vision, Stellantis is committed to achieving carbon net-zero by 2038.

The Auburn Hills wind tunnel, originally built in 2002, can generate wind speeds over 160 miles per hour. It remains a vital tool for Stellantis as the company leads the charge toward a more sustainable and efficient future.

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