Continuous cooling assembly

A continuous cooling unit, comprising:

• a heat exchanger of a vehicle with a first integrated duct, extending between the heat exchanger and a grille positioned upstream of the heat exchanger, and a second integrated duct, extending between the heat exchanger and a vehicle component positioned downstream of the heat exchanger, and wherein a single continuous, 3D printed seamless structure comprises the grille, the heat exchanger, the first integrated duct, and the second integrated duct 3D printed together to form the single continuous, 3D printed seamless structure,
• wherein the single continuous, 3D printed seamless structure is attached to a wheel liner of a wheel via mounting brackets, and wherein the single continuous, 3D printed seamless structure is positioned upstream of the wheel, and wherein the single continuous, 3D printed seamless structure is outside an engine of the vehicle and upstream the engine of the vehicle,
• wherein a first side surface length of the first integrated duct is shorter than a second side surface length of the first integrated duct,
• wherein the first side surface length extends from a top of an inlet end of the first integrated duct to the heat exchanger, and wherein the second side surface length extends from a bottom of the inlet end of the first integrated duct to the heat exchanger,
• wherein the inlet end of the first integrated duct is rectangular, and
• wherein a cross-section of the first integrated duct taken between the inlet end of the first integrated duct and a downstream end of the first integrated duct has an asymmetric and irregular outer geometry along an x-y plane.

A cooling system for a vehicle, comprising:

• a vehicle component;
• and
• a continuous cooling assembly arranged in front of the vehicle component, the continuous cooling assembly configured as a single seamless, 3D printed continuous unit including:
• a grille;
• a non-rectangular cooler positioned behind the grille;
• a first duct extending between the grille and the non-rectangular cooler;
• and
• a second duct extending from the non-rectangular cooler to the vehicle component,
• wherein the single seamless, 3D printed continuous unit is attached to a wheel liner of a wheel via mounting brackets, the single seamless, 3D printed continuous unit positioned upstream of the wheel, and wherein the single seamless, 3D printed continuous unit is outside an engine of the vehicle and upstream the engine of the vehicle
• wherein a first side surface length of the first duct is shorter than a second side surface length of the first duct,
• wherein the first side surface length extends from a top of an inlet end of the first duct to the non-rectangular cooler, and wherein the second side surface length extends from a bottom of the inlet end of the first duct to the non-rectangular cooler,
• wherein the inlet end of the first duct is rectangular, and
• wherein a cross-section of the first duct taken between the inlet end of the first duct and a downstream end of the first duct has an asymmetric and irregular outer geometry along an x-y plane.