MAHLE Unveils Nature-Inspired Radial Blower for Quieter, More Efficient Vehicle Climate Control!

At Auto Shanghai 2025, MAHLE introduced a groundbreaking innovation in automotive air conditioning: a newly engineered radial blower that draws inspiration from nature to enhance performance. The innovative design, modeled after the streamlined shape of penguin fins, optimizes airflow dynamics, resulting in a quieter and more energy-efficient operation for vehicle climate control systems.

The new radial blower, which integrates nature’s principles into its design, represents a major step forward in thermal system technology. By emulating the natural mechanics of penguin fins—known for their efficiency in water—the fan blades have been optimized to provide improved airflow with reduced resistance. This advancement allows the blower to operate approximately 4 decibels quieter, representing a 60% reduction in noise, and achieve an energy efficiency boost of around 15% compared to existing blower models.

“This breakthrough demonstrates the powerful synergy between engineering and intelligent design tools,” said Jumana Al-Sibai, a member of the MAHLE Group Management Board, overseeing the company’s Thermal and Fluid Systems division. “We are proud to showcase our deep expertise in thermal systems while pushing the boundaries of what’s possible in vehicle climate control.”

The newly developed blower is not just quieter; it is also more energy-efficient, which is particularly crucial in today’s automotive landscape where electric vehicles (EVs) demand increased attention to energy consumption. The improved blower design reduces the energy demand on the motor, directly contributing to better fuel economy and longer driving ranges for electric vehicles. This efficiency gain is vital in helping the automotive industry meet sustainability and environmental goals.

The blower’s performance improvements are applicable across a wide range of vehicle categories, from passenger cars to light and heavy-duty commercial vehicles. The technology provides a highly versatile solution for various applications in vehicle climate control systems, offering benefits to both traditional internal combustion engine vehicles and electric vehicles.

MAHLE’s advanced design process, which employed the use of AI-powered tools, was instrumental in accelerating the development of this next-generation blower. According to Uli Christian Blessing, Vice President of R&D for Thermal and Fluid Systems at MAHLE, the company used its AI-driven process to generate and evaluate over 30 million virtual prototypes. This technique, which Blessing describes as “superhuman engineering,” allowed the design team to quickly iterate and refine the blower’s design, ultimately landing on the most effective solution in record time.

The AI-powered design tool significantly reduced the time required for prototyping and testing, enabling MAHLE to bring this innovative product to market faster than traditional development processes would have allowed.

In addition to its quieter and more efficient performance, the new blower also features a compact layout that makes it ideal for use in electric vehicles (EVs). The unit can be strategically positioned in front of the evaporator, which results in a symmetrical and streamlined air conditioning setup, freeing up valuable space in the cabin. This is particularly important for EVs, where space optimization is crucial to maximize battery capacity and passenger comfort.

At Auto Shanghai 2025, attendees have the opportunity to experience the new radial blower firsthand at MAHLE’s 300-square-meter display in Hall 1.2 of the National Exhibition and Convention Center. In addition to showcasing the innovative blower, MAHLE is also demonstrating other forward-thinking solutions, such as a bionic fan designed for fuel cell and electric drive systems and a bionic cooling plate intended for battery thermal management. These elements work seamlessly with electric drivetrains, helping to optimize the performance and efficiency of electric vehicles.

With its nature-inspired design and cutting-edge technology, the new radial blower from MAHLE is set to revolutionize the automotive climate control systems, offering quieter, more efficient, and compact solutions that meet the demands of modern vehicles. The continued integration of advanced engineering tools, like AI, in MAHLE’s product development highlights the company’s commitment to driving innovation in the automotive industry.