A look behind the scenes of the Direnza Research and Development Centre.

Introduction

MVT stands for Multi Vane Technology. This revolutionary new design enhances the efficiency of an intercooler by using vanes in the end tank to redirect air across a much larger area of the core. This leads to reduced intake temperatures and increased engine performance. But how exactly do we design our award-winning MVT intercoolers?

3D Scanning

The first step whenever we undertake a new MVT design project is to remove the front end of the car. With the bumper and intercooler off, we can get to work using our sophisticated 3D scanning equipment.

We begin by scanning all aspects of the OEM intercooler and the front of the car. These scans allow us to accurately measure how much space is available for a new intercooler. The scanner builds three-dimensional computer visuals that can be rotated and viewed from any angle.

Computer-Aided Design (CAD)

Once we have completed the scans, we convert the files into a format compatible with our state-of-the-art CAD software. The scans are used as a base to build our own intercooler. We do this to ensure accurate fitment, by matching OEM end tank positions and mounting points.

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End tanks are individually designed to optimize size, flow and efficiency. The resulting model is overlaid onto the 3D scans we gathered earlier to double-check for clearance around the front of the car.

With the model built, we use CFD modelling analysis to simulate airflow through the end tanks and core. We do this to check an intercooler’s efficiency before we start designing our vanes (MVT).

With the aid of CFD simulations, we can design our vanes to maximize airflow and efficiency through the core; by utilizing as much of the core’s surface area as possible. We are also able to see how the smallest alterations can affect this. We repeat this process until each design meets our high standards.

The CFD analysis above shows the disadvantages of angled end tanks. The sharp angles result in the flow of air being restricted. This would ultimately result in an increased pressure drop across the intercooler and the turbo would be required to work harder to produce boost.

Direnza engineers instead use cast end tanks, which offer exceptional airflow characteristics. This is enhanced further with MVT, which distributes air evenly across the core; Lowering intake temperatures and reducing pressure drop.

3D Printing & Test Fitting

After we have completed our CAD work, the model is printed in full 1:1 scale on one of our three 3D printers. A full intercooler print generally takes a few days to complete. The video below condenses this into just under 1 minute.

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We use this like for like replica to confirm fitment on the car. Our engineers will install the model just as if it were the real thing, noting down any adjustments required. Our team of engineers are so dedicated to the details, we analyse fitment right down to the last millimetre.

Once our team of engineers and designers are happy with the fitment and function of an intercooler, our CAD files will be used to manufacture a one-off sample product. This will be an example of the final production intercooler and thus, will go through another stage of test fitment. This is to confirm nothing has altered between the design and manufacturing stage.

Ready for Production

Once the sample has been successfully installed we can begin to test the intercooler in real-world situations and prove it’s performance on the dyno, directly comparing it with the OEM set-up. Confirming an MVT intercooler’s performance is the last stage in the design process before signing the kit off for production.

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Direnza intercooler kits are developed as direct replacements for the standard set-up. This means a modification to the car’s bumper and surrounding areas are not required. Offering true, bolt-on performance.

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