Unitronic 3” Carbon Intake Assembly and Unitronic 4" Carbon Intake Assembly.

As the initial designs develop; evolution begins with rapid prototyping, utilizing its in-house Stratasys 3D printer. Within hours, Unitronic Engineers are able to have a complete working printed prototype, allowing for test fitments to be performed on the vehicle, functional testing to be completed, and flow data collected to further validate the designs.

To validate its form through function; Unitronic engineers strategically used CFD to maximize its efficiency. Every aspect of the design was studied closely, iteration after iteration, until reaching the maximums governed by the laws of physics. The CFD simulations illustrates how well airflow travels through the system. The primary focus was to achieve laminar flow and minimal pressure drop in all areas of the design. The result of this is an increase in volumetric efficiency.

The CFD sectional of the front air duct shows how laminar airflow is directed towards the air box. It is also seen how the side gills operate; they were employed for safety, in the event the front inlets are obstructed; and for scavenging to eliminate vortices as the high speed air enters the airbox.

Viewing it from the side; laminar flow can be seen as it enters the airbox. As part of the design intent; the use of an integral velocity stack made into the air filter works to promote efficiency.

Unitronic’s pursuit for perfection is applied even in the most minute areas of product design and in this case, Unitronic identified that allowing for ample tolerance for engine movement on an item that is both affixed to a dynamic engine and a rigid chassis. Rather than using traditional silicone for its hose connections, Unitronic’s Carbon Fiber Intake System uses a high-quality, extremely durable EPDM material for its couplers. 
 

This offers a superior amount of flexibility over traditional silicone, while still offering, with its clever design, the rigidity and strength needed to support high-powered 2.5TFSI’s. Taking the design and engineering one step further, Unitronic’s engineers created a design that allows for smooth, laminar airflow on the inside walls, while maintaining flexibility through the means of a non-collapsing structural rib profile. Unitronic's couplers are designed to perfectly align with the bead rolls on the carbon fiber tubes, to ensure a perfect and seamless connection; hose clamp guides ensure perfect alignment.

Taking attention to detail one step further, Unitronic has incorporated a CNC machined and impregnated water drain fitting that allows the factory drain tube to connect directly to Unitronic’s airbox, as it does with the factory box. As with all of Unitronic’s Intake Systems, this unit offers a direct bolt-on fitment, retaining the factory mounting locations, using Unitronic’s own EPDM mounting grommets.

Using its in-house Superflow SF-1020 Flow Bench, Unitronic Engineers further validated designs to ensure that the Unitronic Carbon Fiber Intake System effectively optimizes airflow in a variety of conditions. The OEM intake yielded a peak flow rate of 595 CFM at 28” of H2O (Aq), while the Unitronic Carbon Fiber 4” Intake System achieved 1118 CFM with the RaceFilter for a gain of 88% over the OEM Intake and flowed 1095 CFM with the Sport Filter, a gain of 84% over the OEM Intake.

2019+ DAZA models are supported with Unitronic’s Intake Adapter, allowing a smooth and seamless installation experience.

• Up to 88% increase in flow over stock
• 2/2 Twill prepreg carbon fiber weave
• Autoclave construction
• EPDM couplers
• High-quality stainless steel hose clamps
• Direct bolt-on fitment & EPDM mounting grommets
• Smooth airflow transitions
• Proven power, torque, and airflow gains