MAHLE has pioneered a bionic radial blower for automotive air conditioning systems that improves efficiency while significantly reducing noise development. The development, which has been specially designed for vehicles with challenging installation space, has been guided by an example from nature:

The aerodynamic shape of the fan blades has been modeled after the fins of a penguin, which glide swiftly and quickly through the water. Thanks to this innovative design, the bionic fan is 4 decibels (dB) or 60% quieter in comparison to similar components. At the same time, it is around 15% more efficient as the motor requires less energy due to the optimized configuration. The bionic radial blower can be used in all passenger car classes as well as in light and heavy-duty commercial vehicles.

The penguin fin served as a model for the aerodynamic and slightly curved shape of the fan blades. Source: MAHLE

Modeled on nature and AI-supported design

“Evolution has equipped the penguin with fins that allow it to glide through the water with minimal resistance and, therefore, ultrahigh efficiency. The fin shape served as a model in the optimization process of the impeller of our radial blower,” said Dr. Uli Christian Blessing, vice president R&D thermal and fluid systems at MAHLE. The bionic cooling plate and bionic high-performance fan for electric vehicles enable the automotive supplier to improve efficiency considerably.

The most crucial factor in the rapid development process was a company-owned artificial intelligence (AI) tool. Engineers applied the AI system to create more than 30 million virtual designs in a very short time, and perfect the shape and positioning of the fan blades.

Space-saving and efficient solution

The bionic radial blower sits in front of the evaporator and makes the design of the air conditioner symmetrical and narrow. This creates more space for other components, a crucial advantage especially in battery electric vehicles. This development by MAHLE therefore represents an innovative alternative to conventional fans.