Electric Vehicle Charge Air Coolers

Global Electric Vehicle Charge Air Coolers Market to Reach US$2.6 Billion by 2030

The global market for Electric Vehicle Charge Air Coolers estimated at US$778.3 Million in the year 2024, is expected to reach US$2.6 Billion by 2030, growing at a CAGR of 22.5% over the analysis period 2024-2030. Air Cooled, one of the segments analyzed in the report, is expected to record a 24.2% CAGR and reach US$1.9 Billion by the end of the analysis period. Growth in the Liquid Cooled segment is estimated at 18.6% CAGR over the analysis period.

The U.S. Market is Estimated at US$204.6 Million While China is Forecast to Grow at 21.2% CAGR

The Electric Vehicle Charge Air Coolers market in the U.S. is estimated at US$204.6 Million in the year 2024. China, the world`s second largest economy, is forecast to reach a projected market size of US$399.8 Million by the year 2030 trailing a CAGR of 21.2% over the analysis period 2024-2030. Among the other noteworthy geographic markets are Japan and Canada, each forecast to grow at a CAGR of 20.8% and 19.2% respectively over the analysis period. Within Europe, Germany is forecast to grow at approximately 15.3% CAGR.

Global Electric Vehicle Charge Air Coolers Market – Key Trends & Drivers Summarized

Why Are Charge Air Coolers Becoming Crucial in Electric Vehicle Thermal Management?
Electric vehicle (EV) charge air coolers, designed to manage the temperature of intake air in forced induction systems, are gaining new relevance in the evolving landscape of EV thermal management. While traditionally used in internal combustion engine (ICE) turbocharged vehicles, advanced EV platforms—especially performance and hybrid electric vehicles—now require air cooling systems to maintain optimal thermal efficiency in components such as electric compressors, fuel cells, and high-output e-boosters. Charge air coolers ensure precise temperature regulation, enhancing system performance, energy efficiency, and reliability under varying load conditions.

The shift toward high-performance electric powertrains is pushing manufacturers to design compact, lightweight, and highly efficient charge air cooling systems tailored for EV configurations. Innovations include liquid-to-air intercoolers, integrated thermal modules, and smart electronic valves that dynamically adjust airflow based on real-time temperature data. Tier 1 suppliers such as MAHLE, Modine, Valeo, and Dana Incorporated are investing in hybrid and EV-specific cooling systems that combine air, coolant, and refrigerant-based circuits to serve the unique heat dissipation needs of electric drivetrains. With rising demand for extended EV range and fast charging, thermal regulation systems—such as charge air coolers—are becoming strategic components in overall vehicle design.

Which EV Categories and Powertrain Architectures Are Driving Market Adoption?
Electric charge air coolers are seeing rapid uptake in hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), and fuel-cell electric vehicles (FCEVs), where temperature-sensitive components like electric turbochargers or hydrogen reformers are in use. High-performance battery-electric vehicles (BEVs), especially sports models and electric SUVs, are also employing charge air cooling systems to manage heat during high-load acceleration or prolonged highway driving. Additionally, commercial EVs—including electric trucks and buses—require dedicated air cooling modules for onboard electronics, compressors, and HVAC systems, spurring demand for heavy-duty charge air coolers.

Geographically, the adoption is strongest in Europe and Asia-Pacific, driven by EV production hubs in Germany, China, Japan, and South Korea. China’s push toward fuel-cell vehicles and hybrid buses is particularly notable, as these platforms require advanced charge air cooling systems for both performance optimization and component longevity. Meanwhile, the United States is witnessing growth in performance EV segments and light-duty trucks, where thermal load balancing is critical for battery and powertrain durability. OEMs are integrating compact, lightweight charge air coolers into modular EV platforms to streamline manufacturing and improve energy efficiency.

The Growth in the Electric Vehicle Charge Air Coolers Market Is Driven by Several Factors…
The growth in the electric vehicle charge air coolers market is driven by several technology and powertrain-specific factors. Increasing adoption of turbo-electric compressors, e-boosters, and fuel-cell propulsion systems in high-performance EVs has created demand for precision cooling to maintain intake air temperature within efficiency thresholds. Innovations in heat exchanger materials—such as ultra-thin aluminum alloys and polymer composites—are reducing system weight while enhancing thermal conductivity, making charge air coolers more compatible with EV architecture.
End-use trends are also significant contributors. As EVs become more powerful and multifunctional, particularly in commercial and off-road applications, the need for multi-zone thermal control systems is expanding. Charge air coolers are being integrated into compact thermal management units that handle power electronics, inverters, and motor windings in a single assembly. In addition, regulatory pressure to improve EV energy efficiency ratings and battery lifecycle performance is encouraging OEMs to adopt more advanced, modular cooling technologies. Lastly, the increase in ambient temperature extremes due to climate variability is reinforcing the need for robust charge air cooling systems that can maintain optimal operating conditions across diverse geographies and driving scenarios.

SCOPE OF STUDY:

The report analyzes the Electric Vehicle Charge Air Coolers market in terms of units by the following Segments, and Geographic Regions/Countries:

Segments:
Cooling Technology (Air Cooled, Liquid Cooled); Propulsion (Battery Electric Vehicles, Hybrid Electric Vehicles, Plug-in Hybrid Electric Vehicles); Position (Front-mounted Charge Air Cooler, Rear-mounted Charge Air Cooler); Distribution Channel (OEM, Aftermarket); End-Use (Passenger Cars, Light Commercial Vehicles, Heavy Duty Trucks, Buses & Coaches)

Geographic Regions/Countries:
World; United States; Canada; Japan; China; Europe (France; Germany; Italy; United Kingdom; and Rest of Europe); Asia-Pacific; Rest of World.

Select Competitors (Total 42 Featured) -

• AKG Thermal Systems
• Bell Intercoolers
• BorgWarner Inc.
• Calsonic Kansei Corporation
• Denso Corporation
• Grayson Thermal Systems
• Guangzhou Woshen Auto Radiator Co., Ltd.
• Hanon Systems
• Honeywell International Inc.
• KVR International
• MAHLE GmbH
• Modine Manufacturing Company
• Nissens Automotive
• NRF B.V.
• PWR Advanced Cooling Technology
• Spectra Premium
• T. Rad Co., Ltd.
• Tecumseh Products Company LLC
• Thermasystems Inc.
• Valeo SA

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