SPOTLIGHT - FOCUS RS INTAKE

March 09, 2025

Upgrading the intake on your Mk3 Focus RS is one of the quickest and easiest ways to increase performance, enhance induction noise and give your engine bay an aesthetic boost against the usual sea of dull black plastic.

We're going BTS (Behind The Scenes) and shining a product spotlight on the development of our Mk3 Focus RS HVF (High Volume Flow) carbon fibre induction kit and show you the steps involved, areas of consideration and the ZERONINE DESIGN way of designing and developing the most comprehensive open cone induction solution on the market.

DESIGN CONSTRAINTS & CONSIDERATIONS

Airflow Dynamics and Pressure Drop

A key challenge in induction system design is ensuring smooth, laminar airflow with minimal turbulence while maintaining a low-pressure drop. The pressure drop is the resistance to airflow within the intake system; reducing it allows the turbocharger to operate more efficiently. However, increasing the diameter of the intake piping can disrupt the velocity profile of the airflow, potentially leading to flow separation and turbulence.

Having spent years designing literally thousands of components, including intake systems, we know that the optimum designs include an element of real world trial and error, combined with the latest digital techniques.

Using processes like CFD (Computational Fluid Dynamics) allows us to simulate and analyse the internal airflow characteristics within our HVF carbon filter housing designs to ensure we avoid potential flow restrictions and turbulence zones.

Once the engine bay has been digitally scanned (that's why you can see the small white dots in some of the pictures), we create a three-dimensional environment in which to package the intake kit - once the concept has been optimised and is ready to physically test, it's then turned into reality using one of our 3D printers.

MATERIAL SELECTION MATERIAL SELECTION

We often chose carbon fibre for our performance intakes due to its lightweight properties, thermal insulation characteristics, and mechanical strength. Like you, we enjoy the noise that an open cone setup often provides, but preventing as much engine bay heat from negatively affecting performance is crucial. Unlike aluminum or plastic, carbon fibre does not readily absorb heat from the engine bay, reducing heat soak and ensuring cooler air enters the turbocharger.

Filtration efficiency vs. flow rate

A high-flow air filter must balance airflow improvements with adequate filtration efficiency. Our lightly oiled cotton gauze filters provide high flow rates whilst offering excellent filtration - helped further by the dual-entry design which, in-effect grows the overall surface area of the filter considerably whilst physically maintaining a small size to aid with packaging.

The filter's location is also critical; placing it and shielding it from as much hot air as possible, whilst utilising the factory cold air feed and an additional lower air feed for optimal intake temperatures.

Performance Benefits of a Larger Bore, High-Flow Induction Kit

INCREASED AIRFLOW AND LOWER PRESSURE DROP
A larger diameter intake pipe reduces flow restriction, allowing more air to reach the turbocharger with minimal effort. Lowering the pressure drop across the intake system improves turbo response, reducing lag and enhancing overall engine efficiency. That's why our Focus RS carbon filter housing features an enlarged 73.5mm bore outlet.

ENHANCED TURBOCHARGER EFFICIENCY
With less restriction in the intake, the turbocharger doesn't need to work as hard to generate the desired boost pressure. This reduces compressor workload, lowers intake air temperatures, and increases compressor efficiency, leading to improved power output and turbo (and engine) durability. Try holding your hand over a vacuum cleaner and listen to how much harder it has to work, versus as you remove the restriction - in basic terms, it's the same principle.

IMPROVED THROTTLE RESPONSE AND POWER GAINS
Our carbon induction system improves transient throttle response by reducing intake tract resistance and allowing air to reach the throttle body more rapidly. Depending on what other supporting modifications and the level of tune you're running, power gains of 10bhp are readily achievable, particularly in high RPM ranges where airflow demands are greatest.

IN SUMMARY

The OE intake setup does a good job, but for owners wanting to extract the maximum performance from their Focus RS - or that love the enhanced induction noise from the potent 2.3-litre EcoBoost, the ZERONINE DESIGN carbon intake presents a compelling option; increasing performance, creating a unique induction sound, transforming your engine bays aesthetics and, thanks to a thorough design and development process, exact fitment that makes installation incredibly easy.

This intake is the first of several modular Focus RS upgrades that will become available to support high-power vehicles and those that simply don't want to accept compromises; these include a high-flow rear intake section and a replacement 909 air feed - perfect for track users chasing every last drop of performance!

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