MAHLE has developed a new bionic radial blower for automotive air conditioning systems that delivers improved efficiency while significantly reducing noise. The innovation, unveiled at Auto Shanghai 2025, features fan blades modeled after penguin fins to achieve superior aerodynamic performance.
The bionic fan operates 4 decibels (60 percent) quieter than comparable components while being approximately 15 percent more efficient due to its optimized design requiring less motor energy. This technology can be utilized across all passenger vehicle classes and in light and heavy-duty commercial vehicles.
"The development of the new bionic radial blower underscores our comprehensive systems expertise in thermal management and benefits from the use of artificial intelligence," said Jumana Al-Sibai, member of the MAHLE Group Management Board and responsible for the Thermal and Fluid Systems business unit.
According to Uli Christian Blessing, Vice President R&D Thermal and Fluid Systems at MAHLE, "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."
The development process was accelerated by MAHLE's proprietary AI tool. "The application of artificial intelligence has been enormously useful in the optimization of the bionic radial blower. Our engineers guided the AI and provided it with data and information, enabling it to create more than 30 million virtual designs in a very short time," explained Blessing. "Internally, we are referring to this as 'superhuman engineering'."
The design offers space-saving benefits by positioning the blower in front of the evaporator, creating a symmetrical and narrow air conditioner configuration. This provides more room for other components, particularly valuable in battery electric vehicles.
Visitors to Auto Shanghai can view the new blower at MAHLE's 300 m² stand in Hall 1.2 of the National Exhibition and Convention Center, alongside other innovations including a bionic high-performance fan for demanding fuel cell and battery electric vehicles, and a bionic battery cooling plate. A technical demonstrator at the stand illustrates the connection between electric powertrains and thermal management systems.
The bionic radial blower aligns with MAHLE's future mobility strategy, MAHLE 2030+, which focuses on electrification, thermal management, and components for efficient combustion engines, according to the company.