This study explores in detail how the surface characteristics of soccer balls—specifically the geometric structure of dimples and seams—influence their aerodynamic behavior and overall flight trajectory. Utilizing advanced 3D printing techniques, researchers fabricated eight distinct soccer ball prototypes, each featuring different dimple shapes, including conical, hemispherical, and cylindrical forms, as well as varying seam structures with differences in depth and width. These balls were then subjected to controlled wind tunnel experiments designed to measure critical aerodynamic forces such as drag, lift, and lateral deviation.

The experimental data revealed that both the quantity and shape of dimples had a profound impact on the critical Reynolds number (Re_crit), which is the threshold at which airflow transitions from laminar to turbulent. Soccer balls equipped with conical dimples and deeper seams demonstrated higher drag coefficients but reached supercritical airflow conditions at lower speeds, indicating an earlier transition. This suggests that such features enhance aerodynamic stability under specific conditions. A particularly strong linear correlation (R² = 0.98) was identified between the ratio of surface area occupied by dimples and seams and the corresponding Re_crit value. This finding highlights the importance of surface texture in regulating aerodynamic flow.

Additionally, balls with a reduced number of dimples—ranging from 25% to 50% of the typical count—exhibited lower overall drag and delayed airflow transitions. The study concludes that surface roughness plays a more critical role in ball aerodynamics than previously assumed, surpassing even panel count and basic ball shape.