-01 It Starts With Design

Here at CARRAERO we believe in both form and function. We endeavour to create carbon airboxes that not only deliver maximum performance, but also ensure a striking and unique design.

We start with 3D scan data to ensure accurate fitment to your engine bay. From there we create initial designs balancing package space, aesthetics and performance. 

-02 Flow Analysis

Out of several initial variants we tested, the dual plenum design yielded the most performance from our CFD results. The dual plenum evenly distributes air to each cylinder, by equalising air pressure between the two plenums.

As well as the many benefits a dual plenum design offers, the shape is a nod back to the race winning BMW 320si touring car which ran a dual plenum intake.

-03 Rapid Prototyping

Having concluded on the dual plenum design, our next step is to 3D print our intake manifolds to check for fitment in the engine bay.

Our team operate high-end 3D printing equipment in-house which render amazing finishes and can even print in carbon!

We can print a whole airbox and runners in under 3 hours with our 4 high end printers.

-04 The Dyno Test

Using our 3D printers we are able to print high temperature filament to produce our dual plenum variant for dyno testing.

We use our in house dyno from our BMW Workshop to test our prototype. From here we can make sure we have accurate power gain as well as corroborating our CFD data for accurate results.

-05 Creating The Moulds

Using our Haas VF4 CNC machine, we can create not only our own intake flanges but also our own moulds for carbon fibre production. These are made from billet aluminum and machined with a finish perfect up to 2 microns.

-06 Finishing Touches

After the split moulds are made the carbon is ready for lay-up, curing and finishing. Once our team are happy with the finish we can now sleeve on the flanges and add the all important fixings to the boxes. We even use in-house anodising, to bring some colour to your machined fittings and flanges.

A Shared Vision

Founded by co-owners Marijke and Daniel. Carraero started off as nothing more than a wild idea. Both having backgrounds in BMWs, Marijke in motorsport and Daniel in engine development, the idea behind Carraero seemed an obvious route. In 2024, their BMW workshop, Element Performance launched.

Freddie

Freddie is our in-house composite technician with over a decade of experience in the automotive industry. Freddie prides himself on his keen eye for detail and perfectionism.

Oscar

Oscar is our specialist design engineer and a design professional in the automotive world. With a deep love for cars and engineering, Oscar continues to explore new design trends and technologies, always striving to contribute fresh, cutting edge ideas to the team.