Heavy-duty and industrial cooling systems manufacturer Dolphin Global has adopted physics and engineering AI tools from cloud simulation platform SimScale to accelerate development of heat exchanger and radiator designs. The technology will be used to optimize heat transfer, reduce cooling power requirements, improve resistance to clogging in dirty environments and develop smaller, lighter cooling systems for high-power equipment.

The thermal demands placed on heavy-duty, locomotive and off-highway equipment are becoming harder to solve through conventional, sequential radiator design. AI-powered simulation gives Dolphin the ability to explore far more combinations of core, fin, tube and airflow design – helping engineers find better-performing designs in significantly less time, while balancing thermal performance, pressure drop, weight, durability, packaging and manufacturability.

Dolphin will expand its use of SimScale’s AI and advanced digital simulation tools across its heavy-duty, locomotive truck and bus, and off-highway and industrial ranges in the coming months, using the technology to run computational fluid dynamics and thermal simulations, including shell-and-tube and plate heat exchanger configurations, to optimize thermal efficiency.

Its adoption of the technology deepens Dolphin’s investment in digital-first engineering, enabling its technical team to test and refine thermal and fluid performance earlier and faster in the design cycle, ahead of physical prototyping.

“Our engineering team has always owned every stage of design and validation in-house,” said Nooruddin Jetpurwala, founder, chairman and CEO, Dolphin Global. “Bringing SimScale’s physics and engineering AI and advanced simulation capability into that process enhances our operational efficiency and time optimization. We can now test more configurations, identify issues earlier, and bring validated designs to market faster, without compromising the standards our customers depend on.”

“As equipment and vehicle thermal demands become more complex, supplier engineering teams are increasingly turning to AI and advanced simulation tools,” added David Heiny, co-founder and CEO, SimScale. “By adopting these tools, Dolphin is enabling its engineers to explore up to hundreds more design variants and move beyond conventional approaches and simple, incremental improvements to deliver the type of innovation its customers need.”

Recent news, JLR launches Range Rover Electric with twin 260kW permanent-magnet motors

Cortec has researched how its VpCI-649 BD corrosion inhibitor is being used by several diesel engine manufacturers during hot engine testing and storage. Added to the engine cooling system during testing, the product is intended to protect internal components from corrosion caused by residual water. Cortec says it is also being assessed for use in smaller automotive engines with aluminum components

Why protect engines during hot testing and cold storage?

Residual water left after hot engine testing and fill-and-flush operations can contribute to corrosion of internal engine components during storage. According to Cortec, VpCI-649 BD leaves a protective film of vapor-phase corrosion inhibitors that helps protect engine internals, including where residual moisture is present.

A cure for engine corrosion

In May 2023, a major manufacturer of off-road engines began full-scale testing of VpCI-649 BD to address corrosion concerns. The product is reportedly used as a 3% solution in the cooling system during hot testing and as a 5% solution, combined with glycol, for engines stored in cold climates. Eight months into the trial, the engine maker pronounced its corrosion problem cured. Although VpCI-649 BD was initially used to protect the cast iron of very large engine blocks, it is now being considered for smaller engines with aluminum components, such as those in the automotive industry.

In related news, Smart #2 undergoes global testing ahead of debut

Force Technology is manufacturing valve springs for global engine designer and manufacturer Cosworth to use in the next generation of hypercars.

The company employs 50 specialist staff and sells its precision valve springs to customers worldwide. Managing director Steve Williams explained, “Every valve spring we produce is fully bespoke to the customer’s application. Development programs can take many months – and in some cases several years – as we work closely with customer design engineers to optimize spring performance using advanced engineering tools such as finite element analysis (FEA).

“Once a design is established, the springs progress through a rigorous multistage sampling and validation program. This ensures both manufacturing quality and in-engine performance, with extensive durability and functional testing carried out before production approval.

“In a modern high-speed engine, the valve spring plays a critical role in controlling the movement of the valvetrain under extreme forces and dynamic vibration. At very high engine speeds, maintaining precise valve control is essential to ensure efficient combustion, maximum performance and long-term reliability. Our challenge is to engineer valve springs capable of controlling and damping these forces in some of the world’s most demanding operating conditions.”

Williams noted that Force Technology sources only premium-grade spring wire for its spring valves, because microscopic material defects can have a significant impact on fatigue life and may result in catastrophic engine failure. Manufacturing a high-performance spring valve potentially involves more than 20 production stages.

Every completed spring batch passes through a comprehensive final inspection and quality validation process. When required, springs can also be tested on Force Technology’s in-house engine spin test rig. According to Williams, if material is available and in stock, typical manufacturing lead times range from four to eight weeks.

Force Technology is based in Lancashire in the UK. Prof. Miranda Barker OBE, a spokesperson for Lancashire Business Board, said, “Force Technology’s prestigious contract with Cosworth and its other high-value customers in the UK and worldwide reflects the AEM sector’s resilience, innovation and global competitiveness, playing a critical role in driving productivity, exports and sustainable growth.”

In related news, BorgWarner wins turbocharger contracts with two European OEMs

BorgWarner has secured several turbocharger supply agreements with a major European OEM covering passenger car and van applications. The contracts include extensions of existing programs as well as new business awards, with production scheduled to begin in phases between Q2 2026 and Q2 2029.

“These business wins reflect BorgWarner’s strong turbocharging technology portfolio, our competitive solutions and the trust we have built with this long-standing customer,” said Dr Volker Weng, vice president of BorgWarner and president and general manager of Turbos and Thermal Technologies. “As the industry continues to demand highly efficient combustion solutions, BorgWarner remains committed to delivering advanced turbocharger technologies, reliable supply and strong launch execution for our customers around the world.”

The awarded business includes turbocharger solutions for multiple vehicle programs spanning both gasoline and diesel applications. The portfolio includes variable turbine geometry, twin-scroll wastegate and regulated two-stage turbocharging technologies tailored to a range of engine and vehicle requirements, helping the customer meet increasingly demanding performance, fuel economy and emissions targets across a broad range of applications. The products for these awards will be manufactured at BorgWarner’s facilities in Rzeszów, Poland, and Kirchheimbolanden, Germany.

The company has also secured new business with a major European commercial vehicle OEM to supply a variable turbine geometry (VTG) turbocharger and an exhaust gas recirculation (EGR) cooler for a Euro 7-compliant six-cylinder heavy-duty diesel engine platform. Production is expected to begin at the end of 2028.

“We are pleased to further expand our relationship with this customer on our jointly developed turbocharger and EGR cooler business for a premium heavy-duty engine platform,” added Dr Weng. “This award reflects BorgWarner’s ability to combine advanced technology, strong application engineering and competitive solutions to support demanding commercial vehicle applications. We look forward to bringing this jointly developed solution to market.”

Related news, Partnership to advance hydrogen mobility and research at Georgia Institute of Technology

BorgWarner has secured a seven-year contract extension to supply eight families of engine, machine, power module and battery management system controllers to a world-leading off-highway manufacturer, running through December 2032. The extension builds on decades of partnership with the OEM and spans a broad range of applications, from construction vehicles and marine platforms to stationary power systems.

“BorgWarner has an outstanding relationship with this leading off-highway manufacturer, a customer we have been supplying critical parts to for several decades, and we are thrilled to continue to grow with them as their volumes increase for various market segments and applications,” said Dr Stefan Demmerle, vice president of BorgWarner and president and general manager of PowerDrive Systems. “This contract expansion validates our position as a trusted, long-term propulsion partner that is agile enough to support them and provide tailored solutions as they expand into new, emerging markets.”

BorgWarner’s engine controllers are engineered to enable efficient combustion and minimized emissions across large diesel applications, supporting a wide range of sensors, actuators and heavy-duty injection systems. The company’s machine controllers process operator inputs to precisely direct actuators that control machine movement, ensuring smooth, safe operation in demanding environments such as excavation and construction. BorgWarner will also supply power module controllers for the manufacturer’s electric machines and battery management system controllers.

In related news, Project Cavendish: Mahle hydrogen-fueled 13-liter engine matches diesel performance

Supplying technologies that support vehicle makers across the powertrain evolution, Marelli will showcase its latest e-Transmission Cooling Pump, a system engineered to deliver precise, on-demand oil cooling for modern transmissions. The solution maximizes efficiency, enabling a 30-watt saving compared with the main market benchmark.

With solutions for different propulsion configurations and regional requirements, Marelli will highlight a selection of innovations among the solutions at its booth at Auto China 2026.

The company’s latest e-Transmission Cooling Pump technology is based on a modular solution for transmission control, designed and optimized specifically for e-axles and dedicated hybrid transmissions (DHT), which offers high efficiency (40%), seamless integration and a competitive cost. Leveraging a flexible design which uses brushless technology and integrated electronics, the same base module can also support other multiple applications at the transmission level.

Among its main features, the technology delivers operational efficiency, minimizes energy consumption and improves both electric and fuel economy. Designed for compatibility with mechanical and electronic environments, the solution reduces integration and validation costs. Available in both 12-volt and 48-volt variants, it is the first application of Marelli’s modular smart actuator concept that will address a wide range of automotive applications, ensuring compatibility with current vehicle architectures and emerging multivoltage platforms.

Marelli will also showcase its flex fuel system, which addresses the demand for sustainable, high-performance 3- and 4-cylinder engines by enabling the use of biofuels and ethanol. Automatic fuel detection optimizes fuel efficiency and emission performance, while integrated fuel rail heaters ensure reliable cold starts. The system delivers enhanced flexibility, reduced environmental impact and design and manufacturing tailored to regional market requirements.

Thermal management

In addition to propulsion solutions, Marelli will also present innovations from its Green Technologies division, which focuses on optimizing vehicle thermal energy and exhaust gas management.

Merelli will highlight a selection of technologies designed to maximize thermal efficiency for hybrid and electric powertrains, including the High-Performance Chiller, which enhances battery thermal management in electrified vehicles. Compared with previous designs, the solution delivers higher heat exchange performance, improving battery temperature control and energy efficiency. These gains are achieved through an ultra-fine inner fin structure and a lightweight design, which allow compact dimensions and more uniform refrigerant flow. The system supports high charging rates, while offering strong cost advantages.

The eAxle Oil Cooler is a lightweight and efficient solution for effective heat exchange. It features a new inner fin design that enables compact size and improved thermal performance, combined with an optimized dimple structure that increases water flow speed and reduces dead water areas, boosting cooling efficiency. The miniaturized design delivers space and weight savings, offers flexibility to accommodate different layouts and provides cost advantages while meeting stringent performance standards.

Finally, the company will feature the Full Aluminum Radiator, a solution for electric powertrains. The low-temperature radiator is designed to support efficient and reliable battery cooling for new energy vehicles. The solution enables high heat transfer performance and flexible layout, offering reduced costs and faster cooling.

Auto China 2026 will take place in Beijing from April 24 to May 3.

Related news, HBK integrates torque and NVH testing to enhance end-of-line automotive quality control

General Motors has announced plans to invest more than US$150m in its Saginaw Metal Casting Operations (SMCO) to support the production of the sixth generation of its V-8 engine blocks and heads used in full-size pickup trucks.

This commitment builds on the approximately US$5.5bn in investments GM made in 2025. In January 2023, the company announced a half-billion-dollar investment in its Flint Engine plant for production of the sixth generation of V-8 engines. The investment in SMCO, which includes includes new equipment and tooling, will support this work.

“This significant investment of over US$150m is a clear commitment to the plant and our people,” said John Lancaster, plant director, GM. “By enabling the production of next-generation engine blocks and cylinder heads for full-size trucks, the plant is well-positioned for the future. This not only secures existing jobs but also strengthens the local economy and ensures the plant continues to be an integral part of the automotive supply chain.”

SMCO will continue to produce the fifth generation of GM’s V-8 engine blocks while the plant prepares for the next generation’s production start in 2027.

Related news, Advanced cylindrical cell battery technology powers next-generation electric BMW i7

Swindon Powertrain has sold more than 100 units of its M64 cylinder head kit, a 24-valve upgrade designed to increase performance and rev capability in 964- and 993-generation Porsche 911 engines.

Launched at the end of 2023, the retrofit kit replaces the original two-valve-per-cylinder layout of the M64 air-cooled flat-six with a four-valve architecture, improving airflow and combustion efficiency. The upgrade enables engines to rev up to 12,000rpm and also increases power and torque, with a weight reduction of 3.5kg compared with the standard configuration.

The cylinder heads are cast in the UK using aerospace-grade A356 aluminum CNC-machined in-house at Swindon Powertrain’s Wiltshire facility in the UK. Kits have been supplied to engine builders and specialists globally, including in Europe, the USA, Japan and Australia, for road and track applications.

“Relying on low-flow, two-valve-per-cylinder architectures, the M64 air-cooled engines typically have restricted air flow into the combustion chamber, while the need for heavier springs stresses the rockers and limits RPM,” explained Sylvain Rubio, technical director at Swindon Powertrain. “Our M64 cylinder head kit is helping deliver more power and performance to a new generation of upgraded Porsche 964 and 993 models, benefitting from the latest materials and the finest of CNC machining tolerances.”

The 24-valve design increases peak airflow by around 40% compared with the standard 993 configuration. The kit includes titanium inlet and exhaust valves, along with associated valvetrain components such as springs, caps, collets, shims, finger followers and shafts, as well as camshafts, cam covers and timing drive input.

Among adopters is UK-based Thornley Kelham, which is using the cylinder heads in its limited-edition European RS model. The program will produce 15 vehicles, with customers offered either a 3.6-liter engine delivering more than 380bhp and 290 lb-ft of torque with a 10,000rpm limit, or a 4.0-liter unit producing over 425bhp and 325 lb-ft with a 9,000rpm limit.

“We’re proud to be helping so many engine builders and 911 enthusiasts around the world unlock substantial extra power and torque to create truly standout builds with this high-revving upgrade,” added Raphaël Caillé, managing director at Swindon Powertrain. “Pushing the boundaries of engineering – often beyond what seems conceivable – is a challenge we thrive on. We’re never content to stand still.”

The company is developing other high-performance concepts, including a flat-eight engine. In late 2025, Runge Cars confirmed that it is working with Swindon Powertrain on a 5.3-liter, 32-valve, air-cooled unit.

In related news, flexible, modular hybrid drive targets global EV applications

Swindon Powertrain has hit the decade milestone as a Bosch Motorsport dealer, providing motorsport teams with access to Bosch’s electronics and technical expertise. Since becoming an official dealer in 2016, the company has supported hundreds of UK-based teams across multiple categories, helping them leverage Bosch’s high-performance systems to gain a competitive edge.

The company supplies the full range of Bosch Motorsport products, including sensors, engine control units, display systems and wiring solutions for a wide variety of motorsport applications. As well as component supply, Swindon Powertrain offers in-house engineering support, assisting teams with everything from product selection to system integration and on-track troubleshooting.

“The Bosch brand is synonymous with quality and performance, so to represent this leading name is a privilege,” said Raphaël Caillé, managing director of Swindon Powertrain. “Our dedicated team is proud to mark this long-standing partnership, during which we have worked diligently to help UK race teams with high-performance solutions. We look forward to continuing to help customers achieve their full potential on track.”

Alan Bell, senior manager at Bosch Motorsport UK, added “Every Bosch Motorsport official dealer is carefully selected to ensure they uphold the quality, precision and technical excellence associated with the Bosch brand. We have found an outstanding partner in Swindon Powertrain. Both companies deliver solutions that have been proven time and time again in the toughest of race conditions. We’re delighted to continue this complementary alliance so Bosch Motorsport customers in the UK continue to receive world-class products and the highest levels of technical support.”

Related news, Holyvolt and Wildcat merge to accelerate battery innovation

* Sponsored content

As the automotive industry advances toward a future defined by electrification, hybrid systems and alternative fuels, one technology continues to demonstrate its essential value: gasoline injection. In a mobility landscape where electric, hybrid, hydrogen and advanced combustion engines will coexist, cutting-edge gasoline injection systems remain a cornerstone of efficiency and emission reduction.

Over the past decades, fuel injection technology has revolutionized engine performance and environmental impact. The transition from carburetors to electronically controlled injection systems marked a dramatic step forward, reducing CO and HC emissions by orders of magnitude and significantly lowering NOx. Today’s advanced injectors, capable of delivering precisely metered and finely atomized fuel either into the intake manifold or directly into the combustion chamber, ensure optimal air-fuel mixing and cleaner, more efficient combustion. The result is lower fuel consumption, reduced emissions and enhanced engine responsiveness.

In hybrid vehicles in particular, gasoline injection technology plays a decisive role. By operating the internal combustion engine within highly efficient load ranges, hybrid architectures maximize the benefits of high-precision injection systems. This synergy translates into measurable gains in fuel economy and substantial reductions in harmful emissions, supporting increasingly stringent global regulations without compromising performance or driving pleasure.

At Dumarey Flowmotion Technologies, innovation is at the heart of this evolution. With more than 500 million gasoline injectors produced in Italy and installed in vehicles worldwide, the company stands as a global leader in fuel system engineering. From the pioneering low-pressure Deka models to the latest-generation high-pressure GDI XL5 injectors, every product embodies advanced design, manufacturing excellence and a relentless focus on quality. Complemented by integrated fuel rails and diesel aftertreatment solutions such as RDU and DDU, these technologies form a comprehensive approach to emission control and system optimization.

Dumarey’s manufacturing expertise extends beyond fuel injection to include aftertreatment dosing systems. Our Reductant Dosing Unit is available in three configurations customized for light-duty, medium-duty and heavy-duty applications. The product line includes both air-cooled and liquid-cooled variants, with options for integrated wiring harness assemblies to simplify OEM installation. Our Diesel Dosing Unit (HC injector) provides equivalent functionality for hydrocarbon-based aftertreatment strategies, enabling multiple NOx reduction approaches within a single component platform.

As the industry transitions toward zero-emission powertrains, our engineering capabilities extend to hydrogen industry applications where precise fuel metering and material compatibility with hydrogen gas present unique technical challenges for next-generation propulsion systems.

As the industry embraces a multi-technology future, gasoline injection continues to evolve – smarter, more precise and more sustainable than ever before. It is not simply supporting the transition to cleaner mobility; it is actively enabling it, by combining technological expertise with a clear commitment to sustainability.

Dumarey Flowmotion Technologies is helping drive the automotive industry toward a future where performance, efficiency and environmental responsibility move forward together.