For the P24 RS super sports car, Donkervoort is using additively manufactured liquid-to-air intercoolers for the first time, which were developed in collaboration with the Australian specialist Conflux Technology. The new water-to-air radiators replace conventional air-cooled systems and offer comparable thermal performance with a significantly lower mass. Each of the two aluminum alloy components weighs just 1.4 kilograms – a significant difference to conventional air-cooled systems weighing around 16 kilograms.
“The key to engine performance is keeping the intake air as cold as possible,” said Managing Director Denis Donkervoort. “We challenged ourselves to find the best way to achieve that—and Conflux delivered.
We moved to a liquid-to-air cooler, made using additive manufacturing, from a company that isn’t just on the cutting edge—they’re ahead of it. We gave Conflux our exact specifications, and they delivered a solution so effective, we could even downsize it from the original prototype.”
The components were manufactured using metallic 3D printing and are characterized by optimized geometries, reduced wall thicknesses and tailor-made fin structures. This design freedom not only enables a compact design, but also integration directly into the engine compartment, reducing the length of the intake section by two thirds compared to the previous model. This results in faster engine response and improved weight distribution.
“Our Formula 1 technology is available beyond the track for the first time,” said Conflux Founder Michael Fuller. “We’re scaling it for the high-performance automotive market. For limited-production vehicles like the P24 RS, F1-grade solutions are finally within reach.
Donkervoort approached us with clear cost and performance targets,” Fuller added. “Their clarity and drive made this one of our most exciting collaborations. Within our configurable product line, we could fine-tune everything—from diameter and fin density to overall length—for the most efficient design possible.”
The development shows how targeted additive manufacturing not only reduces component weights, but also contributes to functional improvements in thermally demanding vehicle applications.
Metal Binder Jetting: The Key to Efficient Tool Manufacturing? - Exclusive Insights from INDO-MIM
Fill out the form and get instant access to an exclusive webinar on HP's Metal Binder Jetting 3D printing technology with exciting insights from INDO-MIM.Subscribe to our Newsletter
3DPresso is a weekly newsletter that links to the most exciting global stories from the 3D printing and additive manufacturing industry.
