3D-Printed WCAC Coolers : Conflux and Donkervoort

Conflux Technology and Donkervoort Automobielen have collaborated to develop additively manufactured water-charge air coolers for the forthcoming P24 RS supercar. These air coolers are produced using advanced 3D printing techniques and are constructed from an aluminum alloy, resulting in units that weigh approximately 1.4 kg, compared to around 16 kg for conventional air-to-air coolers with similar thermal capacity. Each component is fabricated with specifically tailored fin geometry, density, and size, which facilitates an efficient cooling process by channeling water through a custom radiator to chill the incoming air before it reaches the engine. This process is designed to optimize the thermal management of the engine and contribute to a more responsive throttle performance.

The compact design of these water-charge air coolers allows them to be positioned within the engine bay, thereby reducing the inlet-tract length by roughly two-thirds. This integration improves overall packaging, enhances weight distribution, and contributes to a more efficient cooling system that supports high-performance engine operation. The application of additively manufactured components in this context demonstrates the scalability of Formula One–grade technology for limited-production vehicles in the high-performance automotive market. Both companies have targeted precise performance and cost parameters, underscoring the potential of advanced manufacturing techniques to meet specific engineering requirements in modern automotive design.

Image Credit: Conflux