CarBench: A Comprehensive Benchmark for Neural Surrogates on High-Fidelity 3D Car Aerodynamics
Authors: Mohamed Elrefaie, Dule Shu, Matt Klenk, Faez Ahmed
Organizations: Department of Mechanical Engineering, Massachusetts Institute of Technology, Cambridge, MA, USA · Schwarzman College of Computing, Massachusetts Institute of Technology, Cambridge, MA, USA · Future Product Innovation, Toyota Research Institute, Los Altos, CA, USA
Benchmarking has been the cornerstone of progress in computer vision, natural language processing, and the broader deep learning domain, driving algorithmic innovation through standardized datasets and reproducible evaluation protocols. The growing availability of large-scale Computational Fluid Dynamics (CFD) datasets has opened new opportunities for applying machine learning to aerodynamic and engineering design. Yet, despite this progress, there exists no standardized benchmark for large-scale numerical simulations in engineering design. In this work, we introduce CarBench, the first comprehensive benchmark dedicated to large-scale 3D car aerodynamics, performing a large-scale evaluation of state-of-the-art models on DrivAerNet++, the largest public dataset for automotive aerodynamics, containing over 8,000 high-fidelity car simulations. We assess eleven architectures spanning neural operator methods (e.g., Fourier Neural Operator), geometric deep learning (PointNet, RegDGCNN, PointMAE, PointTransformer), transformer-based neural solvers (Transolver, Transolver++, AB-UPT), and implicit field networks (TripNet). Beyond standard interpolation tasks, we perform cross-category experiments in which transformer-based solvers trained on a single car archetype are evaluated on unseen categories. Our analysis covers predictive accuracy, physical consistency, computational efficiency, and statistical uncertainty. To accelerate progress in data-driven engineering, we open-source the benchmark framework, including training pipelines, uncertainty estimation routines based on bootstrap resampling, and pretrained model weights, establishing the first reproducible foundation for large-scale learning from high-fidelity CFD simulations, available at https://github.com/Mohamedelrefaie/CarBench.
Figures & tables
Figure 1: Overview of CarBench. The benchmark provides a unified framework for evaluating machine learning models on high-fidelity automotive aerodynamics. It integrates diverse car geometries, CFD-derived surface pressure fields, and automated training pipelines with physics-based and ML metrics. Architectures from multiple model families (GNNs, Geometric Deep Learning, Neural Operators, Transformers, and Triplane networks) are evaluated under a standardized protocol. The framework includes cross-category generalization, uncertainty quantification, computational efficiency analysis, statistical significance evaluation, subsampled vs. full-mesh performance comparison, and wheel aerodynamics prediction. Together, these components enable a comprehensive and domain-specific assessment of aerodynamic surrogate models.
Model
Parameters (M)
Peak Memory (GB)
Mean Latency (ms)
Throughput (samples/s)
MSE (m 4 /s 4 )
MAE (m 2 /s 2 )
RMSE (m 2 /s 2 )
Rtest2
Rel L2
PointNet [ 39 ]
1.67
0.29
1.54
648.85
3350 ± 50
31.12 ± 0.170
57.9 ± 0.44
0.7639 ± 0.0027
0.3803 ± 0.0020
NeuralOperator [ 29 ]
2.10
0.04
2.14
466.36
2130 ± 47
25.02 ± 0.140
46.2 ± 0.51
0.8503 ± 0.0026
0.3016 ± 0.0019
PointMAE [ 37 ]
1.67
0.39
3.11
321.68
1716 ± 39
22.58 ± 0.110
41.4 ± 0.47
0.8791 ± 0.0023
0.2713 ± 0.0016
PointNetLarge [ 39 ]
32.58
1.50
8.29
120.65
1384 ± 37
20.51 ± 0.095
37.2 ± 0.50
0.9025 ± 0.0022
0.2436 ± 0.0013
RegDGCNN [ 17 ]
1.44
27.11
231.98
4.31
957 ± 50
17.41 ± 0.090
30.9 ± 0.81
0.9327 ± 0.0033
0.2006 ± 0.0016
PointTransformer [ 56 ]
3.05
6.65
95.68
10.50
917 ± 82
17.05 ± 0.085
30.3 ± 1.3
0.9359 ± 0.0054
0.1909 ± 0.0024
Table 1: Quantitative comparison on the unseen test set of 1,154 samples across machine learning models, ranked from worst to best by Relative L2 (lower is better). All models are evaluated with batch size 1 on an NVIDIA A100-SXM4-80GB GPU under identical inference settings. Per ISO GUM (Guide to the expression of uncertainty in measurement), uncertainties are rounded to two significant digits and central values are rounded to the same decimal place; precision is standardized per column using the largest uncertainty in that column (MSE (Mean Squared Error): 10, MAE (Mean Absolute Error): 0.01, RMSE (Root Mean Squared Error): 0.1, Rtest2 : 10−4 , Rel L2 (Relative L2 Error): 10−4 ). Here NeuralOperator denotes the voxelized Fourier Neural Operator baseline, i.e. FNO (voxelized), in which the geometry is mapped to a fixed 323 grid rather than through a learned deformation; see the Baseline Models section of the Supplementary Information for the distinction from Geo-FNO and GINO. An asterisk ( * ) denotes a model evaluated from the checkpoint provided by its original authors rather than trained in this work; the corresponding models trained from random initialization on the DrivAerNet++ training split alone are reported in Supplementary Table 6.
Figure 2: Performance–efficiency trade-offs across model families on CarBench. Left: Relative L2 error versus model size (in millions of parameters, log scale). Right: Relative L2 error versus mean inference time (ms) on an NVIDIA A100 GPU. Transformer-based models together with the implicit-field model (TripNet) achieve the best accuracy–efficiency balance, combining low error with compact parameter counts and fast inference. Point-based baselines suffer from higher errors despite lower complexity, while graph-based networks incur large memory and latency overheads. These plots highlight the accuracy–efficiency trade-off across aerodynamic surrogate models, revealing models that are both accurate and scalable. The filled marker denotes the model evaluated from the checkpoint provided by its original authors (AB-UPT * ); the hollow marker denotes the same architecture retrained from random initialization in this work on the DrivAerNet++ training split alone, joined to its counterpart by a grey line. TripNet appears only as retrained in this work. Because parameter count and inference latency are determined by the architecture rather than by the weights, the two AB-UPT variants differ only along the accuracy axis: retraining shifts AB-UPT from a Relative L2 of 0.1358 to 0.1539 .
Figure 3: Qualitative comparison of surface pressure predictions for design E_S_WW_WM_648 from the unseen test set of the DrivAerNet++ dataset. a , Isometric view. b , Side view. In both panels the top row shows the predicted pressure field for each model and the bottom row the corresponding absolute error against the CFD ground truth. While all models capture the general pressure distribution, transformer-based architectures produce smoother predictions that match the CFD reference more closely around the stagnation region and in areas of high curvature, and TripNet gives the smoothest error map, which follows from its triplane-based volumetric sampling. TransolverLarge and AB-UPT * , together with TripNet, form the top-performing group in both views, maintaining spatial coherence and capturing high-pressure regions more accurately than the other baselines. The panels labelled AB-UPT show the author-provided checkpoint, denoted AB-UPT * in the tables.
Figure 4: Pressure prediction on the front-left wheel compared to the CFD ground truth. Models are shown in approximate order of Relative L2 error (worst to best, left to right); PointNet is omitted for space. Wheels can contribute up to 25% of a car’s total aerodynamic drag, making accurate pressure modeling around rotating components critical. Compared to prior open-source datasets, DrivAerNet++ uniquely provides detailed and smooth wheel and tire geometries, enabling evaluation across both open and closed wheel configurations.
Train categories
Test categories
Rel L2
Rtest2
Train
Test
Ratio
Transolver
Transolver++
Transolver
Transolver++
size
size
Fastbacks + Notchbacks
Estatebacks
0.2391
0.2182
0.9088
0.9241
5,388
1,386
3.89
Estatebacks + Fastbacks
Notchbacks
0.1725
0.1729
0.9542
0.9540
5,374
1,403
3.83
Estatebacks + Notchbacks
Fastbacks
0.4894
0.4988
0.6083
0.5933
2,231
5,332
0.42
Estatebacks
Fastbacks + Notchbacks
0.3980
0.4192
0.7446
0.7167
1,108
6,735
0.16
Notchbacks
Estatebacks + Fastbacks
0.4295
0.4483
0.7002
0.6731
1,122
6,718
0.17
Table 2: Cross-category generalization performance of Transolver and Transolver++ across combinations of car design categories. Each row corresponds to a training/test category split using the DrivAerNet++ dataset. Models are evaluated in a zero-shot setting, with no fine-tuning or transfer learning on the test category. We report the Relative L2 error (lower is better) and Rtest2 score (higher is better), together with the training and test set sizes and the corresponding train-to-test ratio. In every experiment the designs of the training categories are split 80/20 into training and validation sets, while all designs of the held-out categories are used for testing. The same category therefore appears with different counts depending on its role: the 5,332 Fastback designs contribute 4,265 training designs when trained on, and all 5,332 are evaluated when held out. These results highlight the models’ ability to extrapolate aerodynamic behavior across distinct vehicle classes under varying data imbalance conditions.
Relative L2
R2
Model
Subsampled
Interpolated
Patchwise
Subsampled
Interpolated
Patchwise
PointNet
0.3763
0.3937
0.3791
0.7700
0.7485
0.7664
NeuralOperator
0.2962
0.3259
0.2987
0.8575
0.8277
0.8549
PointMAE
0.2619
0.3137
0.2670
0.8888
0.8403
0.8839
PointNetLarge
0.2390
0.3203
0.2423
0.9075
0.8337
0.9044
RegDGCNN
0.1954
0.2803
0.1994
0.9378
0.8724
0.9346
Table 3: Subsampled versus full-resolution evaluation on a stratified subset of 61 geometries drawn from the held-out test split, sampled to preserve the archetype proportions of the full split, with all three protocols applied to the same geometries. Subsampled scores a 10,000 -point prediction on those points; Interpolated upscales that same prediction to every node of the full CFD surface mesh ( 3.7 – 5.5×105 nodes, mean 455,000 ) with the radial-basis interpolation; Patchwise instead predicts every node directly using ⌈N/104⌉ disjoint 10,000 -point passes ( 37 – 55 per geometry), and therefore involves no interpolation. Patchwise evaluation recovers almost all of the apparent degradation, showing that the loss attributed to resolution is dominated by interpolation error. † AB-UPT * and TripNet decode arbitrary query points directly, so their patchwise column evaluates every node from a single geometry encoding, with queries chunked only to fit memory, rather than ⌈N/104⌉ independent passes. They are held to the identical interpolated protocol as every other model, with the prediction restricted to the same 10,000 points and upscaled in the same way, so that the column compares evaluation protocols rather than architectures. AB-UPT * is evaluated from the author-provided checkpoint, as in Table 1 .
Model
Median Rel. Error
P50 Error (m 2 /s 2 )
P90 Error (m 2 /s 2 )
P95 Error (m 2 /s 2 )
P99 Error (m 2 /s 2 )
PointNet
0.19
17.57
66.04
101.32
249.43
NeuralOperator
0.15
14.36
53.35
82.93
192.86
PointMAE
0.13
13.17
48.44
72.70
167.14
PointNetLarge
0.12
11.10
46.61
72.06
156.91
RegDGCNN
0.10
9.91
37.03
54.15
111.75
PointTransformer
0.10
9.50
34.77
50.40
103.05
Table 4: Statistical error distribution of surface pressure prediction across models, sorted from worst to best according to Median Relative Error. Median relative error is dimensionless, while percentile errors are reported in absolute pressure units (m 2 /s 2 ). Lower values indicate higher predictive accuracy. Percentiles describe the cumulative distribution of absolute errors across all surface points, capturing both typical and extreme deviations. As in Table 1 , AB-UPT * denotes the checkpoint provided by the original authors, while TripNet refers to our own reimplementation.
Figure 5: Training and validation loss curves for eight models evaluated on the DrivAerNet++ dataset. Each plot shows model convergence behavior over training epochs, with blue indicating training loss and red indicating validation loss. These trends highlight differences in optimization stability and representational efficiency across network architectures for aerodynamic learning.
Figure 6: Surface pressure distributions for representative designs across different car categories in DrivAerNet++. Rows correspond to Estateback, Notchback, and Fastback archetypes under smooth and detailed configurations. The color scale represents kinematic pressure (m 2 /s 2 ), highlighting regions of low pressure over the windshield and roof and high pressure near the front bumper and rear stagnation zones. These examples illustrate the geometric and aerodynamic diversity captured in the dataset.
Figure 7: Comparison of large-scale, high-fidelity, and industry-standard open-source car datasets. DrivAerNet++ (8,150 designs, based on eight parametric models ) provides the broadest coverage, modeling both detailed underbodies representative of internal combustion engine (ICE) cars and smooth underbodies for electric vehicles (EVs). It is also the only dataset to incorporate wheel and tire shape variations, including open and closed wheel designs. DrivAerML ( ∼ 484 designs) is derived from a single DrivAer parametric model, while SHIFT-SUV ( ∼ 2,000 designs) is based on two AeroSUV baseline models.
Figure 8: PCA projection of dataset distributions across DrivAerNet++, DrivAerML, and SHIFT-SUV. Each point represents a car geometry, with DrivAerNet++ spanning a wider and more continuous design space, while DrivAerML and SHIFT-SUV are confined to narrower regions. Notably, DrivAerML lies largely within the coverage of DrivAerNet++, as it is derived from the DrivAer Notchback baseline, one of the eight parametric archetypes used to construct DrivAerNet++. This highlights the geometric diversity and design-space coverage of DrivAerNet++.
Figure 9: DrivAerNet++ dataset geometric statistics. Left: Distribution of point counts across all meshes, showing a consistent resolution with mean and median values around 450K. Middle: Distribution of cell counts, exhibiting a similar bimodal trend and central tendency to the point distribution. Right: Distribution of total surface area, indicating moderate variation across designs with a mean of 33.7 units 2 . Each subplot reports dataset size ( N=8,150 ) and standard deviation, providing an overview of mesh density and geometric uniformity across the corpus.
Model
Training Configuration
Model Architecture
Loss
Epochs
LR
Opt
Batch
WD
Scheduler
Layers
Heads
Embed
Dropout
k -NN
Extra
PointNet
MSE
58 (150)
10−3→10−5
Adam
12
10−4
ReduceLR
–
–
1024
0.3
–
–
NeuralOperator
MSE
100
2×10−3→5×10−7
AdamW
16
10−4
Cosine
2
–
16
–
–
Grid= 323 , M =8
PointMAE
SmoothL1
106 (500)
10−3
AdamW
128
10−2
Cosine ‡
4
–
256
0.3/0.2
–
Efficient
PointNetLarge
MSE
82 (150)
4×10−4
AdamW
8
10−4
OneCycle ‡
–
–
4096
0.3/0.5
–
Residual
RegDGCNN
MSE
200
10−3→10−5
Adam
12
10−4
ReduceLR
3
–
1024
0.4
40
EdgeConv
Table 5: Training and model configurations for all ML baselines, as executed in the runs reported in Table 1 . Epoch entries give the executed count, with the configured budget in parentheses where early stopping intervened; learning-rate entries give the initial and, where a schedule was active, final values. All models are trained on 10,000 points per surface sample with mean squared error loss except where noted.
Study
Dataset
Simulations
Test Size
Design Categories
# Models Evaluated
Flow Regime
Benchmark Availability
Cross-Category Generalization
Uncertainty Quantification
CarBench (Ours)
DrivAerNet++
8,150
1,154
8
11
Steady RANS (OpenFOAM)
✓
✓
✓
Jacob et al. [ 26 ]
VW Real-World*
343
69
32
2
DES (OpenFOAM)
✗
✗
✗
Li et al. [ 30 ]
ShapeNet-Car
889
100
1
5
Steady RANS (OpenFOAM)
✗
✗
✗
Tangsali et al. [ 46 ]
DrivAerML
484
48
1
3
Hybrid RANS-LES (OpenFOAM)
✓
✗
✗
Li et al. [ 30 ]
Ahmed body
551
51
1
5
Steady RANS (OpenFOAM)
✗
✗
✗
Luo et al. [ 34 ]
DrivAerNet++
200
10
3
13
Steady RANS (OpenFOAM)
✗
✗
✗
Table 1: Comparison of existing CFD-based automotive aerodynamics datasets and benchmarks. Each entry lists the corresponding study and dataset, characterized by simulation scale, test set size, number of design categories, number of evaluated machine learning models, flow regime, and benchmark availability. DrivAerNet++ is the largest and most diverse open dataset, supporting full-field aerodynamic supervision, standardized benchmarking, and cross-category generalization across distinct car archetypes. RANS stands for Reynolds-Averaged Navier–Stokes Simulation, DES stands for Detached Eddy Simulation, and LES for Large Eddy Simulation. Bold values indicate the best entries, while underlined values indicate the second best. *Note that the VW Real-World benchmark evaluates only drag coefficients and does not provide full-field flow supervision.
Model
Attention Type
Position Encoding
Dim
Layers
Params (M)
Complexity
PointTransformer
Local k -NN self-attn
Relative offsets pi−pj (MLP)
128
12
3.05
O(Nkd)
Transolver
Slice-based physics attention
Features only (6D)
256
5
2.47
O(NG+G2d)
Transolver++
Slice-based physics attn (Gumbel)
Coord concat (9D)
256
5
1.81
O(NG+G2d)
TransolverLarge
Slice-based attention (scaled-up)
Features only (6D)
384
7
7.58
O(NG+G2d)
AB-UPT *
Anchor self-attn + cross-attn
Rotary Positional Embedding (RoPE)
192
11
6.01
O(Na2+NqNa)
Table 2: Comparison of transformer-based architectures evaluated on DrivAerNet++ for 3D surface-field prediction. The table summarizes the core attention mechanisms, positional encoding strategies, model scales, and computational complexity of each architecture. Complexity notation: N = number of surface points; k = number of nearest neighbors for local attention; G = number of learnable slices/groups in slice-based attention; d = hidden feature dimension; Na = number of anchor tokens in AB-UPT encoder self-attention; Nq = number of query tokens in decoder cross-attention. These quantities determine the computational cost of attention operations across different architectural paradigms.
Model
Parameters
MAE (m 2 /s 2 )
RMSE (m 2 /s 2 )
Rel L2
Rtest2
TransolverLarge
7.58M
11.61
23.61
0.1557
0.9610
Transolver
2.47M
11.83
23.63
0.1558
0.9609
Transolver++
1.81M
11.78
23.72
0.1564
0.9606
RegDGCNN
1.44M
17.08
30.04
0.1985
0.9364
PointMAE
1.67M
17.15
30.63
0.2024
0.9339
PointNetLarge
32.58M
22.07
34.03
0.2248
0.9184
Table 3: Performance of all models trained using the same optimization configuration: Adam with lr=10−3 and no weight decay, MSE loss, a cosine learning-rate schedule, 100 epochs without early stopping, batch size 4 , 104 sampled surface points, and random seed 42 . Results are reported on the held-out test split and sorted by Rtest2 . MAE and RMSE are reported in kinematic pressure units (m 2 /s 2 ).
Model
Input representation
Features
Tensor shape
PointNet
Surface point cloud
[x,y,z]
(10000,3)
PointNetLarge
Surface point cloud
[x,y,z]
(10000,3)
PointTransformer
Point cloud + local kNN ( k=16 )
[x,y,z]
(10000,3)
RegDGCNN
Point cloud + dynamic kNN ( k=40 )
[x,y,z]
(10000,3)
PointMAE
Surface point cloud
[x,y,z]
(10000,3)
NeuralOperator
Voxel grid from 10 k points
Occupancy ( 1 channel)
(1,32,32,32)
Table 4: Input representation, feature format, and tensor shape used by each evaluated model, with the batch dimension omitted. Point-based models sample 10,000 surface points from the full mesh. All models predict per-point surface pressure.
Variant
Input representation
MSE
MAE
RMSE
Rtest2
Δ MSE vs. benchmark
Repeat of benchmark config †
[x,y,z,nx,ny,nz]
575.7
13.09
23.99
0.9595
+2.14%[+1.31,+2.86]
Benchmark configuration
[x,y,z,nx,ny,nz]
563.6
12.87
23.74
0.9604
—
+ signed distance field
[x,y,z,sdf,nx,ny,nz]
578.5
12.94
24.05
0.9593
+2.64%[+1.52,+3.87]
Best architecture, no SDF
[x,y,z,nx,ny,nz]
566.3
12.87
23.80
0.9602
+0.47%[−0.47,+1.31]
Best architecture + SDF
[x,y,z,sdf,nx,ny,nz]
565.4
12.76
23.78
0.9602
+0.32%[−0.51,+1.14]
Table 5: Effect of the input geometry representation on surface-pressure accuracy, with architecture and training held fixed. All variants use the Transolver backbone trained for 200 epochs on the same training designs. Every variant is scored on the same 5,000 measured surface points per design ( 5,770,000 points over the 1,154 test geometries), and errors are in kinematic-pressure units. The final column reports the change in MSE relative to the benchmark configuration with a 95% confidence interval from a paired bootstrap over test geometries ( B=10,000 ). † This variant was configured to remove surface normals, but the option had no effect and the model trained on inputs identical to the benchmark configuration; the row therefore constitutes a repeat run of that configuration, and its deviation provides one observation of run-to-run variability. No representational or architectural change is statistically distinguishable from that repeat-run difference.
Figure 1: t-SNE projection of the test geometries only: the official DrivAerNet++ test split ( 1,154 designs), a 10% sample of SHIFT-SUV ( 200 designs) and 50 DrivAerML cases. Point clouds of 1,024 points per geometry are embedded with the same feature extractor used for Fig. 8, which is projected linearly by PCA; here the same features are projected non-linearly by t-SNE (perplexity 30 , PCA initialization, random seed 42 ). Distances and apparent containment in a t-SNE layout are qualitative and should not be read as quantitative measures of design-space coverage. Restricting the embedding to held-out geometries preserves the structure seen over the full datasets, with SHIFT-SUV forming a separate cluster and DrivAerML confined to a compact region inside the DrivAerNet++ distribution. The DrivAerNet++ test split alone is roughly 23 times larger than a comparable DrivAerML test set and nearly six times larger than a 10% SHIFT-SUV split, which is what allows the confidence intervals in Table 1 to separate models whose errors differ by less than 0.01 Relative L2.
Model
Training source
MSE
MAE
RMSE
Rel L2
Rtest2
AB-UPT *
Original authors
559
10.81
23.6
0.1358
0.9607
AB-UPT
This work
605
12.57
24.6
0.1539
0.9576
Table 6: Comparison between the pretrained AB-UPT checkpoint released by its original authors and the same architecture trained from random initialization in this work. The from-scratch model uses only the official DrivAerNet++ training split and both are evaluated on the same held-out surface-pressure test split containing 1,154 geometries. MSE is reported in squared kinematic-pressure units (m 4 /s 4 ), while MAE and RMSE are reported in kinematic-pressure units (m 2 /s 2 ). Throughout the manuscript, AB-UPT * denotes the checkpoint obtained from the original authors, which is the variant reported in Table 1 and Fig. 2, whereas AB-UPT without the asterisk denotes the model trained from random initialization in this work.
Model
10k
25k
50k
100k
200k
500k
Transolver
0.8
1.9
3.9
7.6
15.0
37.1
Transolver++
0.7
1.7
3.3
6.4
12.8
31.9
TransolverLarge
1.8
4.3
8.5
16.6
33.1
OOM
PointNet
0.3
0.8
1.5
3.0
6.0
15.0
PointNetLarge
1.9
4.1
7.7
15.0
36.3
OOM
PointMAE
0.4
1.0
1.9
3.8
7.6
19.0
Table 7: Peak training memory in GB for one forward-and-backward pass with batch size 1 as a function of the number of input surface points. Measurements were performed on a single NVIDIA A100 GPU with 80 GB of memory. OOM denotes an out-of-memory failure, and “–” indicates configurations that were not evaluated after an earlier out-of-memory failure.
Computational Fluid Dynamics (CFD) is central to race-car aerodynamic development, yet its cost -- tens of thousands of core-hours per high-fidelity evaluation -- severely limits the design space exploration feasible within realistic budgets. AI-based surrogate models promise to alleviate this bottleneck, but progress has been constrained by the limited complexity of public datasets, which are dominated by smoothed passenger-car shapes that fail to exercise surrogates on the thin, complex, highly loaded components governing motorsport performance. This work presents three primary contributions. First, we introduce a high-fidelity RANS dataset built on a parametric LMP2-class CAD model and spanning six operating conditions (map points) covering straight-line and cornering regimes, generated and validated by aerodynamics experts at Dallara to preserve features relevant to industrial motorsport. Second, we present the Gauge-Invariant Spectral Transformer (GIST), a graph-based neural operator whose spectral embeddings encode mesh connectivity to enhance predictions on tightly packed, complex geometries. GIST guarantees discretization invariance and scales linearly with mesh size, achieving state-of-the-art accuracy on both public benchmarks and the proposed race-car dataset. Third, we demonstrate that GIST achieves a level of predictive accuracy suitable for early-stage aerodynamic design, providing a first validation of the concept of interactive design-space exploration -- where engineers query a surrogate in place of the CFD solver -- within industrial motorsport workflows.
Nicholas Thumiger, Andrea Bartezzaghi, Mattia Rigotti +5
Crash simulation is a cornerstone of modern vehicle development because it reduces the need for costly physical prototypes, accelerates safety-driven design iteration, and increasingly supports virtual testing workflows. At the same time, modeling structural crash mechanics remains exceptionally challenging: the response is governed by nonlinear contact, large deformation, material plasticity, failure, and complex multi-body interactions evolving over space and time on high-resolution finite-element meshes. In this work, we introduce CarCrashNet, a public high-fidelity open-source benchmark for data-driven structural crash simulation. CarCrashNet combines component-scale and full-vehicle simulations in a multi-modal format, including more than 14,000 bumper-beam pole-impact simulations with varying geometry, materials, and boundary conditions, together with 825 full-vehicle crash simulations built from three industry-standard vehicle models of increasing structural complexity: Dodge Neon, Toyota Yaris, and Chevrolet Silverado. To establish the reliability of the benchmark, we validate our open-source finite-element workflow based on OpenRadioss against both experimental crash data and the commercial solver Ansys LS-DYNA. We also introduce CrashSolver, a machine-learning model designed for full-vehicle crash prediction from high-resolution finite-element crash data. We further perform extensive benchmarking across the released datasets and evaluate CrashSolver against state-of-the-art geometric deep learning and transformer-based neural solvers. Our results position CarCrashNet as a foundation for reproducible research in structural simulation, crashworthiness modeling, and AI-driven virtual crash testing. The dataset is available at https://github.com/Mohamedelrefaie/CarCrashNet.
Mohamed Elrefaie, Dule Shu, Matthew Klenk +1
Department of Mechanical Engineering MIT Cambridge, MA, USA · Future Product Innovation Toyota Research Institute Los Altos, CA, USA
Accurate aerodynamic prediction is critical for designing fuel-efficient and safe transportation systems such as aircraft and automobiles, yet traditional computational fluid dynamics (CFD) simulations remain computationally expensive and expertise-intensive, severely limiting their use in iterative design and real-time analysis. Existing deep learning surrogates suffer from two major limitations: (i) they are evaluated on datasets with narrow flow-condition ranges, leaving their performance under complex flow conditions undemonstrated; (ii) they treat global flow conditions as a single vector injected uniformly across all surface points, ignoring that different geometric regions experience distinct local flow phenomena, which degrades prediction accuracy under complex flow conditions. To address these limitations, we propose the Flow State Attention Network (FSAN). FSAN separately encodes point cloud and flow conditions, then partitions the geometry into multiple flow states via learnable soft assignments, and uses flow features to update these state representations, which in turn influence point cloud features through state changes. This enables fine-grained, state-specific interaction between geometry and flow information. Extensive experiments on two well-recognized aerodynamic benchmarks demonstrate that FSAN achieves the highest accuracy among the methods compared in this work at a higher computational cost. On Emmi-Wing, FSAN reduces the Relative L2 (REL-L2) error by over 20% compared to the strongest baseline (Transolver), and on DrivAerNet++, it achieves a 10% reduction compared to the strongest baseline (AdaField). These results establish FSAN as a promising neural surrogate on public benchmarks with diverse flow conditions and geometries.
Wenxuan Jin, Jianguo Yao, Haibing Guan +1
Shanghai Key Laboratory of Scalable Computing and Systems · School of Computer Science, Shanghai Jiao Tong University