Global automotive technology leader MAHLE has introduced a revolutionary bionic radial blower for vehicle air conditioning systems, combining nature-inspired design with AI-driven engineering.
Inspired by the aerodynamic fins of penguins, the fan blades of MAHLE’s new radial blower are designed to minimise resistance and maximise airflow efficiency. The result: 60% less noise (equivalent to a 4 dB reduction) and 15% greater energy efficiency compared to conventional systems.
“This development highlights our systems expertise in thermal management and showcases the power of artificial intelligence in accelerating innovation,” said Jumana Al-Sibai, Member of the MAHLE Group Management Board and head of the Thermal and Fluid Systems business unit.
Nature-Inspired, AI-Perfected
MAHLE engineers worked in tandem with a proprietary AI tool that generated over 30 million virtual fan designs, allowing the team to optimise the shape and position of the blades. Described internally as 'superhuman engineering', this collaboration enabled rapid prototyping and precise aerodynamic refinement.
“Penguins glide through water with near-effortless motion thanks to their fin design, which became the blueprint for our impeller blades,” explained Dr Uli Christian Blessing, Vice President of R&D, Thermal and Fluid Systems. This isn’t MAHLE’s first foray into bionic design; previous successes include bionic cooling plates and high-performance EV fans that significantly enhanced thermal efficiency.
Positioned directly in front of the evaporator, the bionic radial blower’s compact and symmetrical layout frees up critical space in modern vehicle architectures—particularly crucial for electric vehicles (EVs) where space optimisation is vital.
Designed for universal application, the blower is suitable for all vehicle classes, from passenger cars to heavy-duty commercial vehicles.
With this innovation, MAHLE not only reaffirms its leadership in thermal management systems but also sets the pace for the integration of biomimicry and AI in next-generation automotive component design.
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