FDS (FLOW DISTRIBUTION SYSTEM)

The IE FDS (Flow Distribution System) has proven to distribute charge air uniformly across the inlet end of the core. In contrast to other intercoolers on the market which rely on natural airflow across the core, our FDS technology uses precisely shaped and placed fins cast into the intake plenum to fully take advantage of the large core volume effectively using the entire core. As a result, the IE FDS intercooler has been proven to reduce intake air temperatures more so than other units available, thus offering the largest power gains possible.

This intercooler is used in record-breaking cars! Increase horsepower and defeat heat soak with the IE front-mount Intercooler Kit for the MK7/MQB 2.0T EA888 Gen 3 engines.

Unlike other intercoolers that are simply put together to fit on the car and offer a larger core, the IE FDS intercooler line receives special treatment from start to finish. The engineering department at IE used Computational Fluid Dynamics (CFD) software to optimize the end tanks and FDS system for minimum pressure drop and maximum flow. Once the end tanks had been designed and flow had been optimized, the 3D models headed over to their 3D printing studio to manufacture the initial prototype.

The 3D printed end tanks fastened onto a production core for testing. To validate the FDS technology, IE tested each model of intercooler in a controlled environment on their in-house engine dyno. A total of 16 temperature probes were placed on the core, with a column of 8 on either side. This allowed them to collect data at multiple points on the inlet side and outlet side of the intercooler to verify temperature distribution across the core. Once that data had been collected, it was analyzed and used to determine if changes in location or pitch of FDS channels were necessary before going to production.