Introduction
In the automotive world, where precision meets passion, we had the privilege of collaborating with Power Division to tackle a unique challenge: creating an air intake system for the Lamborghini Urus, one of the most sought-after luxury SUVs on the market. This was not just another project—it marked a revolution in tuning that redefined our understanding of engine performance.
Working on an air intake for such an advanced vehicle demanded not only cutting-edge technology but also a profound understanding of aerodynamics. Alongside our team of engineers and materials specialists, we focused on innovative solutions to optimize airflow and enhance engine efficiency, essential for the Urus’s performance. However, our role was execution rather than design, faithfully bringing the vision to life.
The project posed several challenges related to design and manufacturing. Overcoming issues like demolding complex components and selecting materials capable of enduring extreme conditions required advanced technologies such as CNC machining and collapsible-core molding techniques.
This endeavor is just the beginning of a larger vision. Plans are underway to relocate production to our facility and expand into new ventures, including air intake systems for fuel-injected engines and the production of bumpers tailored for high-performance vehicles.
In This Article, You’ll Learn:
- The technological innovations behind the new air intake system.
- The challenges Power Division and Carbon Fox overcame during the design process.
- Why aesthetics matter as much as functionality in luxury vehicle tuning.
- What the future holds for our collaboration with Power Division.
1. Technological Innovations in the Air Intake System
About Power Division
Power Division is a leader in engine tuning, specializing in performance-enhancing cooling systems such as intercoolers. Renowned globally, the company delivers cutting-edge solutions that enhance vehicle performance and driving satisfaction, earning a reputation as a trailblazer in luxury vehicle tuning.
Project Objective: Air Intake System for Extreme Conditions
The goal of this collaboration was to produce an air intake system capable of functioning efficiently under harsh conditions while addressing complex geometries, including negative draft angles.
To meet these challenges, the team employed a cutting-edge technique known as “collapsible-core molding.” This method allowed for the production of intricate components that met stringent performance criteria. By incorporating innovative methods, the project succeeded in delivering a high-performance air intake system that has been praised by industry experts.
Collapsible-Core Molding: A Technological Milestone
The collapsible-core method enabled the creation of complex shapes with remarkable precision. Leveraging advanced CNC machining, we achieved unparalleled accuracy in component fitting, resulting in smooth, uniform surfaces—no small feat in such a demanding application.
This technique not only enhanced product quality but also optimized material usage, significantly reducing waste. The outcome was a more efficient production process, improved sustainability, and a solution celebrated for its innovation within the industry.
2. Overcoming Design and Manufacturing Challenges
Technical Obstacles
The project demanded advanced solutions to address numerous technical difficulties. One of the most significant challenges was the development of four-part molds essential for a two-step demolding process. The precision required to align these mold sections was critical to prevent deformation in the final product.
Composite mold production added another layer of complexity. Due to limitations in mold flexing, full molds constructed from robust materials were necessary, ensuring stability but requiring meticulous alignment and craftsmanship.
Addressing Negative Draft Angles
Producing components with negative draft angles posed additional challenges. Traditional composite molds often struggle with such geometries, leading to increased production time and costs. By using CNC-machined solid blocks, we overcame these issues. This method ensured superior precision, minimized the risk of material brittleness or deformation, and delivered robust, stable components.
Additionally, this approach reduced production time and costs by eliminating the need for complex traditional molds, making the process more economical and efficient.
3. Why Aesthetics Are as Crucial as Functionality in Luxury Tuning
Optimizing Material Stability
To minimize material brittleness, we focused on split optimization during the production process. Techniques like CNC machining ensured uniformity and high surface quality, while careful material selection further enhanced durability.
Fine-Tuning Through Controlled Parameters
Proper pressure and temperature settings during autoclaving were critical to achieving even material curing and flawless surface finishes. These parameters were meticulously calibrated to maintain the balance between performance and aesthetics.
Finishing Touches: Nylon Peel Ply and Adhesive Bonding
We used a nylon peel ply to ensure smooth, aesthetically pleasing surfaces—an essential feature for luxury vehicle components. For mounting points, adhesive bonding provided precise, repeatable positioning while simplifying production, reducing costs, and maintaining structural integrity.
4. The Future of Our Collaboration with Power Division
Results and Next Steps
The client expressed great satisfaction with the project outcomes, particularly the quality and finish of the lacquered components.
This partnership represents not only a milestone for our team but also a testament to the potential of innovation in the tuning industry.
