On an electric car, Thule square bars have a noticeable impact on range.

Replacing them with aeroblade is cost prohibitive.

The solution ? 3d print them !

This thing is an attempt to increase the range of my electric car, with Thule Bars installed.

The chosen profile and turbulator is inspired from a Hang glider control bar section.

The provided file is the middle section.
According to me, the 3d printed middle sections works, but it just takes too much plastic.

Print slowly with orientation on the Y axis, because the height is the maximum at which a Anet A8 can print, and movement at this height are scary.

To install, simply remove one feet, and slide one or many printed fairings.

Leave space between fairing to insert a strap for what ever you are carriing on your car.

A heat gun is helpful to soften plastic, once hot, it can be inserted more easily, and remains in place.

I have already noticed that the noise is down but cannot confirm yet that the Kilowatt per kilometer went down. Last summer, I calculated a drop of 7% in range just by adding the bars on roof.

Also, the front bar seems to benefit more from aero fairings, the second one gets more dirty air I guess, and is less noisy.

Printed on a ANET A8, in PETG and a 0.8mm nozzle @ 240 C.