An aftermarket air intake is one of the most popular upgrades you make to your diesel-powered truck. We figured that if all of you have, or plan to, upgrade your factory air intake, then we should show you the technology that goes into building them.
Berry Cater, President of S&B Filters, allowed us unprecedented access to S&B's facilities so we could see first hand how air filters and intakes are designed and manufactured. We listened up and took all the photos we could so we could share what we learned.
S&B develops all of its intake systems in the virtual world before manufacturing a single piece. Rather than build an intake and then try to fit it into a truck, S&B uses laser-digitizing equipment to map the engine compartment. Then it designs an intake that will fit the truck and flow more air. | 
The author's hand is mapped using a laser. As the beam of light is passed over the hand, millions of data points are recorded that are used to generate a 3-D model. | 
In mere seconds, a 3-D image of the hand is created. Once in digital form, this image allows S&B engineers to measure all dimensions (length, width, and height) of the hand (or engine compartment) and use it to model a prototype product. With this technology, S&B could build the author a perfect fitting glove or an air intake that fits like a glove. |
A prototype can then be printed out as a full-scale 3-D object directly from a CAD file using this stereo lithography machine. This quasi-printer lays down layers of light-sensitive resin that build up to form a solid part that can be used to develop molds-or even to test fit a prototype. | 
Once the prototype has been designed, CNC mills are used to build an aluminum form that will allow S&B to build the filter element. | 
The filter media can be tailored to suit any filter application. S&B pleats its cotton-and-mesh element into large sheets that are sheared to size, as needed. |