At Auto Shanghai 2025, MAHLE revealed a breakthrough in automotive air conditioning: a newly engineered radial blower that takes cues from nature to enhance performance. Inspired by the streamlined shape of penguin fins, the fan blades deliver improved airflow dynamics, resulting in quieter and more energy-efficient operation.
Compared to existing models, the new blower runs approximately 4 decibels quieter—representing a 60% reduction in noise—and boosts efficiency by around 15%. This is achieved through refined design that reduces the energy demand on the motor. The blower is compatible with all passenger car segments as well as light and heavy-duty commercial vehicles.
“Our latest development reflects our deep expertise in thermal systems and showcases the powerful synergy between engineering and intelligent design tools,” said Jumana Al-Sibai, a member of the MAHLE Group Management Board overseeing the Thermal and Fluid Systems division.
Uli Christian Blessing, Vice President of R&D for Thermal and Fluid Systems at MAHLE, highlighted the biological inspiration behind the design: “Penguins move through water with remarkable efficiency thanks to the shape of their fins. We applied this principle to optimize the impeller design for minimal resistance and maximum performance.”
The development process was significantly accelerated using MAHLE’s in-house AI-powered tool, which generated and evaluated over 30 million virtual prototypes in a short span of time. “This advanced process, which we informally refer to as ‘superhuman engineering,’ allowed our team to explore a vast range of design possibilities and hone in on the most effective solution,” Blessing explained.
Beyond performance gains, the blower also introduces a more compact layout. By positioning the unit in front of the evaporator, it enables a symmetrical and streamlined air conditioning setup—freeing up valuable space, especially crucial in electric vehicles.
Attendees at Auto Shanghai can explore this innovation firsthand at MAHLE’s 300-square-meter display in Hall 1.2 of the National Exhibition and Convention Center. The exhibit also includes other forward-thinking solutions, such as a high-performance bionic fan for fuel cell and electric drive systems, and a bionic cooling plate designed for battery thermal management. A live demonstration showcases how these elements integrate into electric drivetrains.
This new blower is a key component of MAHLE’s long-term strategic roadmap, MAHLE 2030+, which focuses on vehicle electrification, advanced thermal solutions, and high-efficiency engine components for sustainable mobility.
