Enhancement of a 3D-printed intercooler results in a 10-fold decrease in weight, providing enhanced performance.
In an exciting development for the automotive industry, Dutch supercar manufacturer Donkervoort is set to introduce a groundbreaking component in its forthcoming P24 RS model. The company has collaborated with Australian engineering firm Conflux to create lightweight, compact, and highly efficient intercoolers using Additive Manufacturing (AM) technology.
The new intercoolers, a crucial component in managing the heat generated by the turbocharger, are designed to be a single, one-piece structure with no joints or welds, making them tougher and more durable. Unlike traditional intercoolers, these are sited within the engine bay, rather than mounted at the front of the car. This placement reduces the length of the inlet tract by two-thirds, resulting in quicker throttle response, better efficiency, and optimised weight distribution.
Conflux's design for the intercooler is so effective that it could be downsized still further from the original prototype. The intercoolers, made using high-grade aluminium alloy AlSi10Mg, weigh a mere 1.4kg, a significant reduction from the 16kg of traditional intercoolers. This weight reduction contributes to the overall performance and agility of the P24 RS supercar.
The intercoolers are cooled by an external radiator that is not shared with any other drivetrain cooling system, ensuring optimal cooling efficiency. The fins in the new Conflux intercooler are extremely thin, at 160 microns, which is just two or three times thicker than a human hair. This thinness makes the fins more effective at conducting away unwanted heat.
The 3D-printing technique used for these intercoolers is described by Conflux as Formula 1 technology. The process involves firing lasers into a bed of powdered material to form the objects. This method results in superior thermal performance and packaging benefits compared to conventional equivalents.
The improvements brought about by these innovative intercoolers directly benefit the driver of the Donkervoort P24 RS supercar, enhancing the overall driving experience. The collaboration between Donkervoort and Conflux is a testament to the potential of AM technology in revolutionising the automotive industry.
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