Development & Testing of the Boosted Mentality Motorsports High Performance Air Filter

Engineering the Foundation for Future Boosted Mentality Intake Products

When Boosted Mentality Motorsports began development of its first high performance air filter in 2024, the goal was straightforward: design a filter that delivers measurable airflow improvements while maintaining the engine protection and reliability enthusiasts expect.

The initial development platform was the 2022–2025 Genesis GV70 equipped with the twin-turbocharged 3.5T engine. At the time, this vehicle platform represented our first opportunity to engineer a performance air filtration solution from the ground up.

However, the engineering work performed during that development process did not stop with a single part number. The testing, validation procedures, and filter media selection outlined in this article now serve as the foundation for Boosted Mentality Motorsports air filtration products moving forward.

Today, the same development principles are being applied across new product categories as our lineup continues to expand, including:

- High performance drop-in replacement air filters for additional vehicle platforms

- Cold air intake systems currently under development

- Universal performance filters for custom applications

The work originally completed during development of the GV70 filter program ultimately became the engineering baseline for the entire Boosted Mentality Motorsports intake product lineup.

The Engineering Approach to Performance Air Filtration

Air filters play a critical role in engine performance, efficiency, and long-term durability. Designing a high performance filter requires balancing several key factors that often compete with one another.

A properly engineered filter must balance:

- Airflow restriction

- Filtration efficiency

- Dust holding capacity

- Structural durability

- Maintenance requirements

- Compatibility with modern engine sensors

Maximizing airflow alone is not the goal. Excessively open filter media may increase airflow but compromise engine protection. On the other hand, extremely dense media may provide excellent filtration but restrict airflow and limit performance potential.

Our objective was to engineer a filter media that improves airflow while maintaining strong filtration performance suitable for both daily driven vehicles and performance applications.

Evaluating Common Filter Media Technologies

Before selecting a filtration material for production, we evaluated several widely used filter technologies found across both OEM and aftermarket applications.

These included traditional paper filters, oiled cotton filters, and synthetic dry-flow media.

Traditional paper filters are commonly used by OEM manufacturers because they provide strong filtration efficiency and long service intervals. However, their dense fiber structure can create higher airflow restriction, particularly as the filter becomes loaded with debris.

Oiled cotton gauze filters use layered cotton material saturated with filter oil. The oil helps trap contaminants while allowing relatively high airflow. However, these filters require periodic cleaning and re-oiling, and improper oil application can sometimes affect sensitive mass airflow sensors used in modern engine management systems.

Synthetic dry-flow filtration media uses engineered polymer fibers arranged in a uniform structure designed to balance airflow and particle capture. Because this media does not rely on oil to capture particles, it simplifies maintenance while reducing the risk of sensor contamination.

After evaluating multiple material samples and conducting airflow and durability testing, synthetic dry-flow filtration media ultimately proved to provide the most balanced solution for our performance goals.

Filter Media Technical Specifications

The filtration media selected for Boosted Mentality Motorsports production filters is designed to deliver high airflow while maintaining effective filtration performance.

Filter Media Type: High-Flow Synthetic Dry-Flow Filtration Media
Basis Weight: 2,518 g/m² (74.3 oz/yd²)
Media Thickness: 2.0 mm (0.079 in)
Maximum Pore Diameter: 150 µm (5.9 mil)
Average Pore Diameter: 146.2 µm (5.8 mil)
Tensile Strength: 140 N (31.5 lbf)
Airflow Permeability: 2,800 L/m²·s (>550 CFM/ft²)
Filtration Efficiency: 95% @ 10 µm

The 2 mm thick filtration media allows particles to be captured throughout the depth of the filter rather than only on the surface. This improves dust holding capacity while allowing airflow to remain stable as the filter accumulates contaminants over time.

Technical Data Sheet & Engineering Overview (PDF Download)

For enthusiasts, engineers, and customers who want a deeper look into the filtration media and testing results, we have created a technical overview brochure that summarizes the engineering specifications behind our high performance air filters.

The downloadable PDF includes:

- Detailed filtration media specifications

- Airflow permeability data

- Filtration efficiency metrics

- Material construction overview

- Engineering highlights from our development process

Preview the brochure below or download the full technical document for reference.

Download the Technical Air Filter Engineering Brochure (PDF)

Understanding Airflow vs Filtration Balance

One of the biggest challenges in filter design is balancing airflow and filtration efficiency.

Dense filtration media can capture smaller particles but may significantly restrict airflow. Highly open media may provide excellent airflow but fail to protect the engine from fine contaminants.

Our filtration media achieves a measured airflow permeability of 2,800 liters per square meter per second, which is just over 550 cubic feet per minute per square foot of media area.

At the same time, the filter maintains 95% filtration efficiency for particles measuring 10 microns.

For reference, a typical human hair measures approximately 70 microns in diameter, illustrating how small these captured particles actually are.

Performance Validation Testing

Once the filtration media was selected, real world testing was performed to evaluate its effect on engine performance and efficiency.

Testing was conducted using a completely stock 2022 Genesis GV70 3.5T to ensure results reflected realistic operating conditions.

Both dyno testing and real world driving tests were conducted.

Dyno Testing Procedures

Dyno testing was performed to evaluate horsepower and torque changes associated with improved intake airflow.

Testing conditions included:

Vehicle: Stock 2022 Genesis GV70 3.5T
Dyno: Dynojet - same machine used for all runs
Environment: Controlled dyno room conditions
Runs performed: 10 total runs

Peak horsepower and peak torque values were recorded for both the OEM filter and the Boosted Mentality Motorsports filter.

Dyno Testing Results

The Boosted Mentality Motorsports filter consistently produced higher peak numbers compared to the factory filter.

OEM Filter Results
Peak Horsepower: 286.17 HP
Peak Torque: 304.68 lb-ft

Boosted Mentality Motorsports Filter Results (Final)
Peak Horsepower: 315.47 HP
Peak Torque: 319.52 lb-ft

These results represent peak gains of approximately 29 horsepower and 14 lb-ft of torque during testing.

Actual gains may vary depending on vehicle modifications, tuning, environmental conditions, and other factors.

Performance horsepower, torque, and fuel efficiency improvements are dependent on numerous factors such as other modifications done to the vehicle, proper vehicle maintenance, fuel type, driving habits, altitude, and other conditions.

Fuel Economy Testing

In addition to performance improvements, we evaluated whether improved airflow could influence fuel economy during normal driving conditions.

Testing parameters included:

Vehicle: 2022 Genesis GV70 3.5T
Location: St. Louis, Missouri region
Driving conditions: Typical city and highway driving
Environmental conditions: Temperature and humidity recorded

Test distances included 50, 100, 250, 500, and 1000 mile intervals.

Five independent testing cycles were completed.

Fuel Economy Results

OEM Filter Average Fuel Economy
Approximately 20 MPG with ±1.5% variance

Boosted Mentality Motorsports Filter Average Fuel Economy
Approximately 22 MPG with ±1% variance

This represents an average improvement of approximately 2 MPG under typical driving conditions.

During one extended highway trip exceeding 750 miles, the vehicle achieved 26.1 MPG under ideal conditions, though this result represents an optimal scenario rather than typical driving results.

Surface Filtration vs Depth Filtration

Air filters capture contaminants using two primary mechanisms.

Surface filtration occurs when particles accumulate on the outer surface of the filter media. This is common with dense paper filters and can lead to increasing airflow restriction as debris builds up.

Depth filtration captures particles throughout the thickness of the filter media rather than only on the outer surface.

The 2 mm thick synthetic filtration media used in Boosted Mentality Motorsports filters allows contaminants to be captured throughout multiple fiber layers, improving dust holding capacity and maintaining airflow stability over time.

Particle Size Reference

Understanding particle size helps illustrate the scale of filtration.

Human hair: approximately 70 microns
Pollen: 10 to 100 microns
Fine dust: approximately 10 microns

Boosted Mentality Motorsports filters capture 95% of particles measuring 10 microns, helping protect the engine while maintaining strong airflow performance.

Why Synthetic Dry-Flow Media Was Selected

After extensive evaluation, synthetic dry-flow filtration media provided the best overall balance of performance and reliability.

Advantages include:

High airflow permeability
Strong filtration efficiency
Durable fiber structure
Washable and reusable construction
No oil required during maintenance

Because the filter operates without oil, it simplifies maintenance and eliminates the possibility of over-oiling affecting sensitive engine sensors.

Maintenance and Service Life

Boosted Mentality Motorsports filters are designed to be washable and reusable, allowing them to be serviced multiple times throughout the life of the vehicle.

Cleaning requires only a few simple steps.

Remove the filter from the airbox. Regular “maintenance” cleaning is as simple as blowing out with compressed air. If heavily contaminated, rinse with water and mild cleaning solution. Allow the filter to dry completely before reinstalling.

Because the filtration media is dry-flow, no oil is required during servicing.

Building the Future of Boosted Mentality Intake Products

Although this development program began with the Genesis GV70 3.5T platform, the testing procedures and engineering principles established during this project now guide development of all Boosted Mentality Motorsports intake products.

As our product lineup expands, the same filtration media selection criteria, airflow testing standards, and performance validation methods will be applied across:

- New vehicle specific drop-in replacement filters

- Cold air intake systems currently under development

- Universal performance air filters for custom applications

This ensures every Boosted Mentality Motorsports intake product maintains the same balance of performance, filtration efficiency, durability, and ease of maintenance.

Conclusion

The development of the Boosted Mentality Motorsports high performance air filter began as a focused effort to improve airflow for the Genesis GV70 3.5T platform. Through careful media selection, engineering analysis, and real world testing, the project ultimately produced far more than a single product.

It established the engineering foundation for an expanding lineup of intake products designed for enthusiasts who demand both performance and reliability.

At Boosted Mentality Motorsports, our commitment remains the same: deliver performance products backed by testing, real data, and thoughtful engineering.