MAHLE presents a pioneering 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 modelled 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 optimised design. MAHLE is setting a new benchmark with this innovation. “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, MAHLE Group Management Board and responsible for the Thermal and Fluid Systems business unit. The bionic radial blower can be used in all passenger car classes as well as in light and heavy-duty commercial vehicles. The technology group is presenting the innovation to the public for the first time at the Auto Shanghai trade fair in China. The motor show is taking place from April 23 through May 2, 2025, at the National Exhibition and Convention Center (NECC) in Shanghai.

Modelled 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 optimisation process of the impeller of our radial blower,” said Dr Uli Christian Blessing, Vice President R&D Thermal and Fluid Systems, MAHLE. The Group has already used nature as a guide on several occasions in the past. 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 AI tool. “The application of artificial intelligence has been enormously useful in the optimisation 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 Uli Blessing. “Internally, we are referring to this as ‘superhuman engineering’.” The MAHLE engineers were able to use this to work out the perfect shape and positioning of the fan blades and quickly produce prototypes.

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.

MAHLE at Auto Shanghai 2025

Visitors to Auto Shanghai can see the new bionic radial blower for the first time at the MAHLE stand in Hall 1.2 of the National Exhibition and Convention Center in Shanghai. Also to be discovered are the bionic high-performance fan for particularly demanding fuel cell and battery electric vehicles, as well as the bionic battery cooling plate for electrified vehicles. At the centre of the 300 m2 MAHLE stand is a technical demonstrator that provides a simple and clear explanation of the importance and the connection between the electric powertrain and thermal management system. Electrification, thermal management, and components for efficient, clean combustion engines are the three fields of the future that MAHLE is pursuing as part of its strategy MAHLE 2030+ for the future of mobility.