Asger Risom
Electric vehicles may be quiet, but unwanted cabin sounds can still intrude. Now, engineers have turned to penguin flippers and artificial intelligence to design a fan that slashes ventilation noise by 60%.
Electric vehicles may be quiet, but unwanted cabin sounds can still intrude. Now, engineers have turned to penguin flippers and artificial intelligence to design a fan that slashes ventilation noise by 60%.
Silent Cars, Loud Vents
Without a combustion engine to drown them out, sounds like air conditioning fans become more noticeable in electric vehicles — and often annoyingly so.
An Unexpected Critic
Zunder CEO David Pérez, a vocal EV advocate, admitted to being bothered by the sharp sound of electric car ventilation systems — an issue magnified by the quiet cabin.
Penguins: Nature’s Noise Solution
To tackle the problem, Mahle engineers looked to penguins. Their flippers are hydrodynamically efficient, creating little turbulence — a trait that inspired a new fan blade design.
Millions of Simulations
Using generative AI, Mahle simulated over 30 million blade variations. The algorithm tested countless angles and profiles to find the quietest, most efficient solution.
Turbocharger-Like Design
The final result resembles the blades of a turbocharger. It’s compact, symmetrical, and optimized to move air with minimal resistance or sound.
Real-World Impact
The bionic fan reduces operating noise by 4 decibels — a drop equivalent to 60% less perceived sound during vehicle operation.
Efficiency Gains Included
Quieter isn’t the only win. The design also cuts energy use by 15%, meaning less battery drain and more efficient performance for electric vehicles.
Compact by Design
With EVs reshaping internal layouts and reclaiming front trunk space, components like Mahle’s fan must be small — and this one fits the bill.
Premium Silence
Automakers like Mercedes tune even details like A-pillars to reduce cabin noise. A low-noise fan reinforces the premium feel that EV buyers expect.
AI Meets Biomimicry
Mahle calls the process “superhuman engineering” — using artificial intelligence to push nature-inspired designs far beyond human capacity.
A Standard in the Making
As electric vehicles continue evolving, the penguin-inspired bionic fans may become the industry norm — blending silence, efficiency, and smart design into one essential component.
This article is made and published by Asger Risom, which may have used AI in the preparation
