Customers & Partners

Zero-E Racing is a Menlo Park, California based organization that promoted downhill "gravity" races during 2004-2007. 3dyn, llc was contracted for the 2006 and 2007 seasons to develop racing vehicles, based on automotive design studio concepts. The vehicles were completely developed in-house, from scratch, except for off the shelf go-kart or bicycle components.

2006 Gravity Series Vehicles

For the 2006 Zero-E Gravity Series racing season, 3dyn was contracted to develop a production run of five gravity cars, capable of achieving nearly 70 MPH, downhill, with no means of propulsion other than gravity. Through the use of high-performance downhill mountain bike components, a sophisticated Tig Welded Aluminum chassis, and a fiberglass composite aerodynamic shell, customer teams were allowed to compete against factory works teams such as Chrysler, Honda, and Mazda. The 3dyn developed cars proved their performance, taking 2nd Place at the Jack's Peak race near Laguna Seca in Monterey, California.

2006 Gravity Car Collection in Front of 3dyn Offices

With a concept sketch provided by the Pininfarina studio in Italy, by noted Ferrari Designer Maurcio Corbi, 3dyn developed CAD models for the structure, aero, packaging, and suspension, creating a vitual model of the vehicle prior to commencement of fabrication. High density foam master models of the body were cut via CNC in the 3dyn facility, and hand finessed and polished to produce fiberglass molds, then 5 sets of body shells. High precision bend, machined, and welded Aluminum were joined to create a safe and rigid chassis, with integrated roll hoop and 4 point safety harness. Some vehicles were painted to a high gloss, while others were vinyl wrapped with complex graphics. Some vehicles were later sold at the Barrett-Jackson Auction.

2007 Gravity Series Vehicles

For 2007, an even more challenging task was achieved. A series of 3 different vehicles, each with 3 copies, for a total of 9 vehicles were required. Designs from Bentley studio leader James Shaw, Aston Martin studio's Julian Wiltshire, and Porsche Design studio's Mark Clarke provided designs for 3dyn to develop in to working racing vehicles.

Close-up of Bentley Gravity Car

With the new designs, new challenges were also created. The cars for the 2007 were to be developed as monococque chassis, without metal frames from the previous year. For this design, carbon fiber prepreg was used to mold the three different body styles, but the surface quality had to be high enought to allow for one clear coated carbon fiber body, and 8 with show car quality paint jobs. Not an easy task.

High density foam master models were again used, this time to fabricate high temperature fiberglass molds in which to mold vacuum bag and oven cured carbon fiber and epoxy prepreg. The carbon fiber bodies were mated to CNC machined aluminum bulkheads, which were then fitted with carbon fiber, aero shaped axles. The axles were then fitted with CNC machined, adjustable steering components, allowing for camber, caster and toe adjustment.

A carbon fiber steering wheel, with an integrated GPS display provided by MaxQData of Sammamish, WA was used to control the vehicles. Due to an early snow at the racing venue in Lake Tahoe, CA, only some light exposition runs were performed, never being able to show the true ability of the cars.

For more information

Contact Zero-E Racing:
Zero-E Racing

Block Sanding Aston Martin Master Model

Bentley CAD Model

Porsche Design Studio Renderings

Porsche Composite Tooling Fabrication

Aston Martin Final Assembly

Carbon Fiber Steering Wheel with GPS Display