Modular intercooler block

A method for a modular intercooler block, comprising:

• fabricating a direct metal printed and configured intercooler block;
• forming a first core header and a second core header, the first core header being substantially identical to the second core header;
• disposing a multiplicity of cooling fins between on a surface of each of the first core header and the second core header;
• arranging a multiplicity of first countersunk holes on an outwardly-facing surface of the first core header in an alternating row and column configuration, and a multiplicity of second countersunk holes arranged in an alternating row and column configuration on an outwardly-facing surface of the second core header, wherein the modular intercooler block has a first distance that extends from the outwardly-facing surface of the first core header to the outwardly-facing surface of the second core header, and wherein each of the first and second core headers have an inwardly-facing surface that is opposite to the outwardly-facing surface;
• and
• coupling a plurality of core tubes directly coupled to the first countersunk holes and the second countersunk holes;
• wherein an inlet of an inlet tank is in fluid communication with the multiplicity of second countersunk holes;
• and
• extending each of the plurality of core tubes from each of the multiplicity of first countersunk holes in the first core header, through the multiplicity of cooling fins following an undulating path across the multiplicity of cooling fins, to each of the respective multiplicity of second countersunk holes in the second core header, wherein each of the plurality of core tubes has a second distance that extends from one end to another end that is opposite to the one end and wherein the first distance is greater than the second distance, wherein the undulation path is such that each of the plurality of core tube tubes extends through each cooling fin once and only once;
• wherein a phase-shift between the undulating paths of adjacent undulating core tubes is 90 degrees;
• and
• wherein the second distance is equal to a third distance from the inwardly-facing surface of the first core header to the inwardly-facing surface of the second core header.