Water Charge Air Cooler (WCAC)

Engineered for motorsport and high-performance vehicles. Configurable to optimize pressure drop and heat rejection.

Water-to-Air Cooling for High-Performance Engines

The Conflux Water Charge Air Cooler (WCAC) is engineered for high-performance systems that demand consistent power, seamless integration, and proven durability. Designed with advanced additive manufacturing and validated through computational fluid dynamics, it transforms charge-air cooling into a measurable performance advantage, balancing power, reliability, and cost-cap compliance.

High-Performance Automotive

Conflux WCACs provide performance vehicle manufacturers and OEMs with tailored thermal solutions that enhance powertrain output, extend reliability, and optimize packaging. The configurable design allows seamless integration into complex vehicle architectures, enabling consistent cooling performance across endurance road use, delivering measurable efficiency gains and long-term durability for hypercars and performance road vehicles.

Motorsport

In competitive racing, cooling defines competitiveness. Conflux WCACs can be tuned for extreme powertrain demands where stable charge-air temperatures sustain lap-after-lap performance. Combining lightweight construction with precision configurability to manage pressure drop and heat rejection, teams gain the balance of speed, reliability, and compliance to cost-cap regulations.

Configurable Intercooler Designs for Any Engine

Conflux’s Water Charge Air Coolers are easily adapted to enable seamless integration into high-performance engines. Additive manufacturing enables ports, connectors, and manifolds to be printed directly with the Conflux Core™ , creating plug-and-play connections to both charge-air and coolant circuits in a compact, monolithic design. Internal geometries are fully configurable allowing for customized fluid flow paths.

This design flexibility means faster development, lower overall program costs, and cooling systems that perform reliably in racing and high-performance environments.

Why Choose Conflux Water Charge Air Coolers?

Conflux water charge air coolers deliver race-proven thermal performance through advanced additive manufacturing technology. Engineered for automotive’s most demanding environments, these cooling solutions combine superior engineering with production-ready reliability to give teams a measurable competitive advantage.

Adaptable Form Factor

Conformal packaging enables rapid customization for unique engine bay layouts.

Tailored Core Geometry

Cross-flow and counterflow cores to achieve minimum air-side pressure drop without sacrificing cooling efficiency.

Seamless Integration

Adapts rapidly to tight packaging with ports and mounts printed monolithically as one piece.

Embedded with Conflux Core™

The Conflux Core™ is our proprietary internal geometry developed through additive manufacturing. It combines ultra-fine structures and tunable flow paths to deliver high-efficiency heat transfer, controlled pressure drop, and system-specific adaptability. The Conflux Core™ is the foundation that makes compact, lightweight, and production-ready cooling possible.

Maximised Heat Transfer in Compact Designs

The Conflux Core™ is engineered to deliver superior thermal exchange efficiency within tight packaging constraints by leveraging ultra-fine fin geometries for exceptionally high surface area density.

Tailored Performance for System Requirements

Fin density and geometry can be adjusted to balance pressure drop with heat rejection, ensuring consistent fluid distribution and avoiding maldistribution common in conventional cores.

Higher Thermal Effectiveness

Counterflow configurations provide significantly greater thermal effectiveness compared to parallel-flow designs, enabling improved energy recovery and overall system optimisation.

Lightweight, Compact, and Scalable

Beyond raw performance, the Conflux Core™ reduces system mass and volume, creating new design freedoms for motorsport and high-performance auto applications. Its scalable, adaptable architecture forms the foundation for next-generation thermal management.

Serial Production Ready

Conflux Production System, our vertically integrated platform, transforms high-performance water charge air coolers from bespoke motorsport solutions into scalable serial production components for automotive manufacturers. Our configurable, production-ready designs enable rapid adaptation to different specifications and packaging constraints, making serial production seamless and cost-effective.

Production-Ready Quality

Every water charge air cooler undergoes rigorous validation including pressure testing, vibration testing, and thermal cycling to ensure proven durability under extreme conditions. This comprehensive testing regime backed by our AS9100D and ISO9001 certifications reduces the risk of field failures and supports long-term reliability requirements.

Accelerated Development Cycles

Conflux Production System (CPS) eliminates traditional tooling requirements and reduces development timelines by up to 60% compared to conventional manufacturing methods. This enables rapid iteration from concept to production-ready components, allowing automotive manufacturers to respond quickly to design changes, performance optimization requirements, or regulatory updates without the delays and costs associated with tooling modifications. Teams can validate and refine designs through multiple prototyping cycles within weeks rather than months, significantly reducing program risk and accelerating time-to-market.

Superior Value Through Performance

Conflux WCACs deliver exceptional cost-effectiveness by providing significantly enhanced cooling performance at competitive pricing. The substantial improvements in pressure drop reduction, thermal efficiency, and weight savings translate into measurable power gains and operational benefits that far exceed the initial investment. This performance-per-dollar advantage enables manufacturers to achieve superior cooling capabilities while maintaining budget targets and competitive positioning.

Conflux designs Water Charge Air Cooler for Donkervoort's P24 RS

Download our latest case study to see how the Conflux WCAC outperformed industry-standard microtube coolers, delivering an impressive lower air-side pressure drop in reduced core volume.

Let's discuss your water charge air cooling needs.

Discuss your cooling challenges with our engineer team. Schedule a meeting to explore a WCAC solution tailored to your system requirements.

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Latest News

September 30, 2025