Metal 3D Printed Heat Exchanger: Conflux Builds 1.4kg Water-to-Air Intercooler for Donkervoort P24 RS
Conflux Technology, a company specializing in the design and manufacturing of heat exchangers, has produced a metal 3D printed water-to-air intercooler for the Donkervoort P24 RS supercar in 2025.
This part continues to leverage the advantages of 3D printing—creating lighter, more compact, and higher-performing components—and is considered a major innovation for the year by Conflux.
Constructed from aerospace-grade aluminum alloy, it weighs only 1.4 kg, compared to 16 kg for a conventional device with similar performance.
Integrated Design Shortens Intake Plumbing by Two-Thirds
Official reports state that this radiator achieves an integrated design. It utilizes a dual-module architecture integrated directly between the turbocharger and the throttle body, shortening the total intake plumbing length by two-thirds and significantly improving engine responsiveness.
Each component employs biomimetic structures optimized via Computational Fluid Dynamics (CFD), including cooling fins with a 0.2–0.5 mm gradient thickness, thin walls measuring only 0.8 mm, and spiral internal flow channels.
Cylindrical Shape Increases Cooling Surface Area in Limited Space
The radiator features a generally cylindrical shape, which helps provide a larger cooling surface area within a limited space while enabling more efficient spatial layout.
Side port interfaces allow connection to other components via piping, which can be used to transport coolant or other heat dissipation media. This design allows the radiator to work in tandem with other cooling systems to form a complete thermal cycle, thereby enhancing cooling efficiency.
Spiral Internal Fins Enhance Air Contact Area
The internal spiral fins are another characteristic feature. The design significantly improves cooling efficiency by increasing the surface area in contact with air.
As air flows through these spiral fins, heat can be dissipated more thoroughly; compared to traditional straight-plate designs, this optimized structure effectively reduces operating temperatures.
Compact Structure Allows Engine Bay Placement
The new intercooler will be supplied by VanDerLee, a Dutch supplier that has previously provided parts for McLaren and Koenigsegg, and will be paired with the latter’s turbochargers.
Because of its compact structure, it can be placed inside the engine bay rather than at the front of the vehicle as in previous models. Reports indicate that this configuration helps shorten the overall plumbing, further improving vehicle response speed.
Each Component Customizable According to Engineering Requirements
Each component is 3D printed to order, allowing for customization of fin geometry, density, and size based on engineering priorities.
It also integrates custom-sized thin-walled radiators, enabling the entire system to provide better cooling performance with less coolant and a smaller surface area.
Why Are Heat Exchangers Particularly Suited for Metal 3D Printing?
This case once again demonstrates the advantages of metal additive manufacturing for thermal management components. Traditional manufacturing processes are constrained by tooling, molds, and assembly methods, whereas metal 3D printing can directly manufacture complex internal flow channels, thin-walled structures, variable-density cooling fins, and biomimetic geometries.
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