The Ducati V4 brake cooling cowl, from the bike to a test fit

The cowl scoops air from beside the front axle and ducts it back onto the Brembo caliper. There are no new brackets: the part hangs off the caliper's radial mount bolts, so it has to fit around hardware that is already there.

Capture

The assembly starts with the hardware the part has to live with: the 330 mm rotor, the radial caliper mount with its two bolt bosses, and a silhouette of the fork leg. Everything the cowl touches or has to clear is in the model before the cowl is.

Model

The duct is swept from the scoop beside the axle back to the caliper. The bolt ears sit on the mount bosses and clamp between the fork lugs and the caliper, so the caliper bolts hold the cowl too. The left part is modeled and the right is a mirror.

• Model the hardware first; design the part into the space that is left.
• Put the split line where the printer can reach it, not where it looks tidy.
• Fillet the inside of the duct. Sharp turns are where the flow separates and where the print cracks.

Test fit

CFD

I ran a lattice-Boltzmann LES solve around the assembly (2.5 mm grid, wheel stationary) with a modeled radial caliper. Tracing the flow backward from the inlet shows the air the scoop actually catches: about three in four of those streamlines reach the caliper, arriving as a jet at roughly half free-stream speed. Inlet speed is about a third of free stream, so some of the oncoming air spills around the scoop. That points at exit area and a smoother turn into the caliper for the next revision. It is a flow-pattern check, not a number to design to.

The first print is a prototype to check fit on the bike; the production part is PA6-GF. The check is a track session with the RaceBox logging: if the part stays put through the fast sections and the fit is still clean after the session, it ships. That data is the same data behind the Corner IQ demo.