MAHLE has introduced an innovative bionic radial blower designed to enhance automotive air conditioning systems. Inspired by nature, the aerodynamic fan blade design takes cues from the sleek, hydrodynamic fins of a penguin—allowing for smoother airflow, improved efficiency, and reduced noise.
Tailored for vehicles with tight installation spaces, this breakthrough delivers a remarkable 60% noise reduction—equivalent to 4 decibels—compared to conventional blowers. At the same time, energy efficiency is boosted by approximately 15%, thanks to the blower’s optimized motor design.
“This new bionic radial blower highlights our deep expertise in thermal management systems and reflects the integration of artificial intelligence in our development processes,” said Jumana Al-Sibai, Member of the MAHLE Group Management Board and head of the Thermal and Fluid Systems business unit.
The new blower is suitable for all passenger cars as well as light and heavy commercial vehicles. MAHLE will showcase the innovation for the first time at Auto Shanghai 2025, held from April 23 to May 2 at the National Exhibition and Convention Center (NECC) in Shanghai.
Inspired by Nature and Powered by AI
“Evolution has shaped the penguin’s fins to move through water with minimal resistance and exceptional efficiency. We took inspiration from this design to optimize the impeller of our radial blower,” said Dr. Uli Christian Blessing, Vice President R&D Thermal and Fluid Systems at MAHLE. The company has frequently looked to nature for innovation, with previous examples including a bionic cooling plate and a high-performance fan for electric vehicles—both significantly enhancing efficiency.
A key driver behind the rapid development of the bionic radial blower was MAHLE’s proprietary AI tool. “AI played a pivotal role in the optimization process. Our engineers guided the system with data and parameters, allowing it to generate over 30 million virtual designs in a very short time,” Blessing explained. “We call it ‘superhuman engineering’ internally.” This powerful collaboration enabled the team to determine the ideal blade shape and positioning, accelerating the move to prototyping.
Compact, Efficient, and Future-Ready
MAHLE’s new bionic radial blower is positioned directly in front of the evaporator, enabling a more symmetrical and compact air conditioning design. This streamlined setup frees up valuable space for other components—an especially critical benefit in battery electric vehicles. With this innovation, MAHLE presents a cutting-edge alternative to traditional fan systems.
MAHLE at Auto Shanghai 2025
Visitors to Auto Shanghai 2025 can experience the debut of the bionic radial blower at the MAHLE booth in Hall 1.2 of the National Exhibition and Convention Center in Shanghai. Also on display are the bionic high-performance fan—designed for the demanding needs of fuel cell and battery electric vehicles—and the bionic battery cooling plate for enhanced thermal management in electrified drivetrains.
At the heart of MAHLE’s 300 m² exhibit is a technical demonstrator that clearly illustrates the crucial interplay between the electric powertrain and thermal management systems. These innovations reflect MAHLE’s strategic focus, MAHLE 2030+, which targets three key areas for the future of mobility: electrification, thermal management, and clean, efficient combustion technologies.
