Prometheus Eco Racing (NTUA) / Case study

PYRFOROS IV.

Fourth-generation ultra-efficient prototype for the Shell Eco-marathon — designed, built, and raced with one target: the most kilometres out of every kilowatt-hour.

PYRFOROS IV on track at Shell Eco-marathon Europe 2026, race number 717

FIG. 01 — PYRFOROS IV · Shell Eco-marathon Europe 2026

Role
Mechanical Lead
Result
7th overall
Efficiency
~202 km/kWh
Award
Vehicle Design Award
01

Overview

PYRFOROS IV is the fourth-generation prototype from Prometheus Eco Racing, NTUA's Shell Eco-marathon team. As Mechanical Lead, I directed the car's structural design, composites manufacturing, and aerodynamic development from concept through competition.

The car finished 7th overall at Shell Eco-marathon Europe 2026 at ~202 km/kWh — roughly 2.5× the efficiency of the prior generation — and won the Vehicle Design Award.

Scope of my work
  • Structural design & CFRP monocoque
  • CFD-driven bodywork development
  • FEA validation of chassis & suspension
  • Vehicle dynamics tuning
02

Chassis & composites

The CFRP monocoque and body panels were engineered and laid up in-house to minimise mass while meeting scrutineering stiffness and safety requirements.

CFRP RVE (Representative Volume Element) micromechanical stress model used to derive the monocoque's laminate properties
FIG. 02 — CFRP RVE micromechanical model, laminate homogenization
03

Aerodynamics & CFD

CFD surface pressure distribution and streamlines over the frozen PYRFOROS IV exterior geometry
FIG. 03 — CFD surface pressure & streamlines, frozen geometry

Bodywork development was driven by CFD to cut aerodynamic drag at race speed.

04

Structures & vehicle dynamics

Chassis and suspension components were FEA-validated ahead of scrutineering, and the vehicle dynamics setup was tuned to balance rolling resistance, stability, and efficiency targets.

Double-wishbone front and trailing-arm rear suspension and steering assembly, CAD render
FIG. 04 — Double-wishbone / trailing-arm suspension & steering assembly
05

PYRFOROS III → PYRFOROS IV

Every decision above traces back to one lap-simulation energy budget for the Poland circuit: 48% of lap energy lost to aerodynamic drag, 26% to rolling resistance (mass). Measured against the previous-generation car, here's where that went:

PYRFOROS III PYRFOROS IV
Curb mass
130 kg → 80 kg −38%
Drag coefficient (Cd)
0.299 → 0.111 −63%
Drag area (CdAf)
0.343 m² → 0.098 m² −71%
Aero power @ 35 km/h
~193 W → 55.2 W −71%
06

Results

Shell Eco-marathon Europe 2026

7th overall

Efficiency

~202 km/kWh

Award

Vehicle Design Award Winner