Dutch car manufacturer Donkervoort has worked with Conflux on a thermal application for the upcoming P24 RS supercar. Together, they produced 3D-printed, ultra-lightweight water-charge air coolers that are “lighter, smaller, and more efficient than anything previously seen in production cars.”
The result: a pair of aluminium-alloy sculptures weighing just 1.4 kg each, compared to 16 kg for conventional air-to-air units with similar thermal capacity. These custom water-charge air coolers (WCAC) provide sharper throttle response, improved packaging, and reduced weight.
“The key to engine performance is keeping the intake air as cold as possible,” said Managing Director Denis Donkervoort. “We challenged ourselves to find the best way to achieve that—and Conflux delivered.”
“We moved to a liquid-to-air cooler, made using additive manufacturing, from a company that isn’t just on the cutting edge—they’re ahead of it. We gave Conflux our exact specifications, and they delivered a solution so effective, we could even downsize it from the original prototype.”
Thanks to their compact form, the air coolers now sit within the engine bay rather than at the front of the car—reducing the inlet-tract length of the outgoing engine by two-thirds. The result: quicker response, greater efficiency, and optimised weight distribution.
These Conflux units—designed and built in Australia—join Van der Lee’s billet turbochargers as part of Donkervoort’s high-tech evolution of the PTC engine.
Water is cooled through an external radiator, then redirected to chill the intake air before it enters the combustion chamber. That precision enables consistent, high-performance delivery—under any condition. The system also integrates a custom-sized, thin-wall radiator that provides more cooling with less coolant and a smaller surface area than its predecessor.
“Our Formula 1 technology is available beyond the track for the first time,” said Conflux Founder Michael Fuller. “We’re scaling it for the high-performance automotive market. For limited-production vehicles like the P24 RS, F1-grade solutions are finally within reach.”
Donkervoort was among the first to adopt Conflux’s production-ready air coolers, utilising cylindrical designs placed directly between the turbochargers and throttle bodies of the PTC engine. Each component is 3D-printed with tailored fin geometry, density, and size, grounded in engineering-first principles.
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