- The new aerodynamic system can reduce diesel consumption by 3 gallons for every 1,000 miles traveled.
- The design of AeroSlider improves airflow around the trailer, reducing drag.
- The system is easy to install, lightweight, and can pay for itself within a year.
- Independent tests confirm that the system effectively saves fuel and meets market demand.
A U.S. company recently showcased a redesigned aerodynamic system that has the potential to reduce fuel consumption by up to three gallons for every 1,000 miles traveled. This system, named "Trailer AeroSlider," was developed by FlowBelow Aero, an engineering and manufacturing company based in Texas. The company focuses on developing aerodynamic solutions for Class 8 heavy-duty trucks and trailers. The new device was unveiled at the American Trucking Association's Management Conference & Exhibition, held from October 17 to 20 in Charlotte, North Carolina, which highlights commercial vehicles and trucking technology.
According to company representatives, the system can reduce drag around the trailer's wheels and suspension components. Additionally, it weighs less than 30 pounds and takes no more than an hour (approximately 45 minutes) to install, with no driver involvement required after installation, allowing for a payback period of one year.
AeroSlider Design and Functionality
Fuel consumption increases on highways due to significant aerodynamic drag caused by the truck's large, boxy shape. This drag increases fuel consumption at speeds over 31 miles per hour (50 kilometers per hour). Aerodynamic improvements have primarily focused on the front and sides of the trailer. However, the wheels and suspension components also generate turbulence. Therefore, the development of AeroSlider aims to address this issue by improving airflow around the trailer's dual-axle components. The device does not block airflow but instead directs it outward and backward, reducing turbulence around the suspension and the rear of the trailer, thereby lowering aerodynamic drag.
AeroSlider is designed for the wheels, suspension, and chassis around the trailer's dual axles.
The system can also move with the trailer's sliding suspension. Generally, truck operators regularly adjust the position of the trailer axles to distribute cargo weight and comply with road weight limits. Since AeroSlider moves with the axles, its aerodynamic components maintain the proper position without additional adjustments. FlowBelow first launched AeroSlider in 2017, and the new version features a single improved cover instead of separate central and rear covers. The redesigned system saves more fuel, is lighter, costs less, has a shorter installation time, and is compatible with nearly all dry freight or refrigerated trailers.
Independent Test Results and Market Impact
Fuel savings were confirmed during testing, which involved computational fluid dynamics simulations, wind tunnel experiments, and field tests. The independent testing company MVT Solutions evaluated its performance in June 2026, using a 2019 International LT trailer pulling a loaded 53-foot dry freight trailer. The initial configuration included trailer side skirts and wheel covers. The addition of the redesigned rear cover and flow-through mud flaps was able to reduce fuel usage by 1.77 gallons per 1,000 miles.
Meanwhile, independent tests confirmed that the trailer wheel covers could save an additional 1.23 gallons over the same distance. The launch of the device coincides with high diesel prices in the U.S. Data cited by the company shows that as of October 12, the national average price reached USD 6.179 per gallon, translating to a potential savings of USD 18.54 for every 1,000 miles. For a trailer that travels 100,000 miles annually, this could mean approximately USD 1,854 in fuel savings each year.
Josh Butler, President and CTO of FlowBelow, emphasized in a press release: "Our goal with AeroSlider is to develop an aerodynamic system that can pay for itself within 18 months in a typical regional or long-haul fleet, assuming diesel prices are USD 3.00 per gallon. Based on current fuel prices, even for fleets that travel 30,000 miles a year, the payback period could be less than 12 months."
Item Specification System Weight Less than 30 pounds Installation Time Approximately 45 minutes Fuel Savings 1.77 gallons per 1,000 miles
Market Potential of the New Aerodynamic System
As fuel prices rise, the demand among truck operators for cost reduction becomes increasingly urgent. The launch of AeroSlider aligns perfectly with market needs, effectively reducing fuel consumption and offering an easy installation, providing operators with a viable solution. This technology not only enhances transportation efficiency but also reduces carbon emissions, in line with current environmental trends. With more supporting test data, this system is expected to gain widespread adoption in the commercial vehicle market, further promoting sustainable development in the industry.