The new fan, modelled on nature, is adaptable for passenger cars

At the IAA Transportation 2024 in Hanover, MAHLE unveiled what it describes as a groundbreaking innovation: a bionic high-performance fan designed for commercial electric and fuel cell vehicles.
MAHLE says this fan, inspired by the wings of an owl – one of nature’s quietest hunters – significantly reduces noise, addressing a key challenge in e-mobility.
MAHLE engineers used AI to optimise the fan’s blades, drawing on the noise-reducing characteristics of owl plumage.
It says the result is a fan that reduces truck noise by up to four dB(A), effectively halving the sound output.
This quieter performance is especially beneficial during nighttime charging in residential areas or at service stations.
Additionally, MAHLe says the fan is 10 percent more efficient and 10 percent lighter than conventional designs, further enhancing vehicle performance.
MAHLE’s new bionic fan isn’t limited to commercial vehicles, it is also adaptable for passenger cars.
“We learn from nature,” MAHLE Head of Development Thermal Management, Dr Uli Christian Blessing, said.
“Nature inspired our successful bionic battery cooling plate, and now our new fan, modeled after the silent owl, sets a new standard for quiet and efficient operation.”
The fan, available in power ranges from 300 watts to 35 kW, caters to both small electric cars and large fuel cell trucks.
Prototypes are already being tested by various manufacturers.
To further reduce weight, MAHLE applied bionic principles to develop a lighter, yet stronger, fan cover and carrier.
Efficient thermal management is crucial for electrification, and MAHLE says it excels in both fields.
At IAA, the new fan was featured as part of MAHLE’s comprehensive approach to fuel cell trucks. This included a fully functional fuel cell, thermal management systems, and a heavy-duty electric axle integrating two SCT electric motors with a total output of 520 kW.
MAHLE also introduced its new evaporative cooling system, which it says boosts cooling capacity by 50 kW in the same space, reducing fan usage and hydrogen consumption by up to 1.5 percent.
Additionally, MAHLE’s Power Cell Unit for hydrogen engines ensures robust and reliable operation for this climate-neutral technology.

For more information, visit www.mahle.com