2019-2022 RAM 6.7L Intercooler R&D

As Banks’ Mechanical Engineering Design Team continues their development of the 2019-22 RAM 6.7L Cummins intercooler, they’re analyzing the stock geometry and airflow characteristics. This is where their 3-D scans come in handy. Last week the team captured the geometry of the stock intercooler on Banks’ own 2020 RAM 3500 HD High Output. 

Using the stock intercooler data coupled with the dimensions of the chassis and engine bay, they’re able to create a boundary box from which to work. From here, engineers can see what space is afforded to them and start designing larger, more free-flowing components such as the intercooler itself and boost tubes. As we’ve written before, designing an intercooler is an incredibly complicated balancing act. Increasing the unit’s ability to cool the charge air may adversely affect boost pressure. Or, increasing its cooling may adversely affect the airflow needed to cool the radiator immediately behind it.

When you’ve increased the intercooler’s ability to cool the charge air and maintained maximum boost pressure, while allowing as much air as possible to flow through its face, you’ve won the battle and made a better intercooler. Anything less, and your design gets scrapped.