A US company has just presented a redesigned aerodynamic system that has the potential to reduce fuel consumption by up to three gallons for every 1,000 miles on the road.Dubbed the Trailer AeroSlider, the system was made by Texas-based engineering and manufacturing company FlowBelow Aero. The firm develops aerodynamic solutions for Class 8 semi-trucks and trailers.The new device was revealed at the American Trucking Associations’ Management Conference & Exhibition. Running from October 17 to 20 in the city of Charlotte, North Carolina, the event focuses on commercial vehicles and trucking tech. According to company representatives, the system can slash air resistance around the trailer wheels and suspension components. Additionally, it weighs less than 30 lbs, can be installed in under an hour (roughly 45 minutes), and requires no driver involvement once fitted. The system could cover its initial cost within a year.Reducing fuel consumptionAt highway speeds, trucks experience significant air resistance, also referred to as aerodynamic drag, due to their large, boxy shapes. This resistance increases fuel consumption, particularly at speeds above 31 miles per hour (50 kilometers per hour). Aerodynamic improvements mostly focus on trailer fronts and sides. Wheels and suspension parts, however, also generate turbulence. The AeroSlider was hence developed to address this issue, improve airflow around the trailer’s tandem axle assembly.Instead of blocking the airflow, the fairings redirect it outward and backward as it passes the wheels. This reduces the turbulence around the suspension and in the trailer’s wake, and lowers the aerodynamic drag.The AeroSlider targets the wheels, suspension, and underbody surrounding the trailer tandem.Credit: FlowBelow AeroThe system can also move with the trailer’s sliding suspension. In general, truck operators regularly adjust the position of trailer axles to distribute cargo weight and comply with road weight limits. Since the AeroSlider moves alongside the axles, its aerodynamic parts remain properly positioned without the need for additional adjustments.FlowBelow first unveiled the AeroSlider in 2017. The new version features a single, improved fairing, rather than a separate center and rear fairings. The redesigned system saves more fuel, weighs less, and costs less, and takes less time to install. It is also designed to fit almost any dry van or refrigerated trailer.Fuel savings confirmed in testsThe redesign involved computational fluid dynamics simulations, wind-tunnel experiments, and track testing. In June 2026, independent testing company MVT Solutions evaluated its performance using 2019 International LT tractors pulling loaded 53-foot dry van trailers.The initial configuration already included the trailer side skirts and wheel covers. Adding the redesigned rear fairings and flow-through mud flaps slashed fuel use by 1.77 gallons per 1,000 miles. At the same time, separate testing confirmed that the trailer wheel covers could save another 1.23 gallons over the same distance.The device comes amid high US diesel prices. Figures cited by the company show that the national average hit USD 6.179 per gallon on October 12. This translates to potential savings of USD 18.54 every 1,000 miles. For a trailer covering 100,000 miles annually, that could mean approximately USD 1,854 in yearly fuel savings.‘Our goal with the AeroSlider was to develop an aerodynamic system that could pay for itself in less than 18 months for a typical regional or long-haul fleet at USD 3.00 per gallon diesel,” Josh Butler, FlowBelow president and CTO, stressed in a press release. “At today’s fuel prices, payback can be less than 12 months, even for fleets whose trailers travel as little as 30,000 miles per year.”