Hyundai Ioniq Electric 28kWh wheel trim inserts

thingiverse

Since I saw <a href="https://www.myminifactory.com/object/3d-print-nissan-leaf-allow-rim-area-inserts-76399/">Paul Kennets Nissan Leaf alloy rim aero inserts ("Leaf Petals")</a> I wanted to make some for my Hyundai Ioniq Electric. Well, about 8 months later and I now have a working design and a full set printed. I've encountered no issues at speeds up to 120km/h. When I tested (<a href="https://www.ioniqforum.com/threads/wheel-covers-and-their-impact-on-efficiency.36492/">a different design on my more open winter rims</a>) I found an 7% increase in efficiency at 110km/h. I assume these will net less due to the stock rims smaller stock aperture and they look more aerodynamic. Nevertheless. These inserts replace the stock ones and screw into place with the OEM screws. Takes about 10 minutes per wheel to install if you know where to lift and how to get the wheel off. I'm not an expert at 3D-modeling, nor at 3D-printing so if you want to remix the design feel free to do so. Or if you have some good tips on how to best print these please share. I had some trouble with under extrusion that a little overlap might fix, also the screw pylons have broken on some prints so check yours prior to installing(take a screw of the OEM parts on the car and pre-thread the pieces to make sure they hold). Mine are printed at .16mm, 80mm/s. Probably a little to fast for my Ender 3 pro. Takes about 6h to print including time to cool. You will obviously need 4 full and 1 vale 1 cap per wheel. The cap threads the wrong way(left to tighten), I made the thread upside down and was to lazy to change it. I've printed with tree supports touching build plate, results in a lot of sanding but the pieces came out structurally good that way(especially the diagonal piece). I've printed in PETG, sanded them down and coated with clear coat to give some resistance to the muck and grime on our roads. ABS should be even better if you can, PLA will warp in the sunlight. Overall, its been a fun project, if it was worth it... I don't know, but I'll share it anyway. Probably looks nicer if painted in the cars colour or black/gray. Happy Driving