PRESSURE REDUCING VALVE BODY

In order to have a lightweight hydraulic valve, this stackable valve body has been redesigned to be 3D printed.

 

The additive manufacturing allows a high reduction of the material used for the production, and the final weight of this valve has been reduced by 60% less.

 

With the addition of the pressure-reduction cartridge, we have created a direct operated pressure reducing valve in stainless steel. While, normally, the standard pressure reducing valves are made in steel zinc plated. Moreover, during the pressure tests, the 3D printed valve has demonstrated the same results as the

traditional manufactured valves.

 

To test the materials variety offered by additive manufacturing, this hydraulic valve has been 3D printed in stainless steel, aluminum and in Maraging steel. The first material offers an high corrosion resistance, and it is widely used for special applications, such as oil&gas, yacht and naval. aluminum is lightweight and Maraging steel is known for possessing superior strength and toughness

without losing malleability.

3D printing advantages:

 

  • Weight reduction
  • Possible choice between high performing materials
  • Optimized performances

 

HYDRAULIC SPOOL

Hydraulic spools 3D printed

This spool has been redesigned in order to be 3D printed with new holes forms, such as oval holes and square holes.

 

These shapes are impractical with traditional manufacturing, in particularly with CNC machining, while with additive manufacturing complex geometries are now feasible.

 

Indeed, with the new holes forms, our idea is to increase the passing area of oil inside the spool, allowing lower pressure drop. Therefore, the new design with additive manufacturing offers an higher performance.

 

Moreover, with the ability to build complex geometries, we have consolidated more components into one piece and our 3D printed spool is one single part. This allows to simplify the manufacturing process and reduce assembly time.

3D printing advantages:

 

  • Availability of geometric forms impossible with traditional machine
  • Ability to combine multiple parts into one
  • Possible better performance than the traditional manufacturing
Hydraulic spools 3D printed

HYDRAULIC VALVE BLOCK

Hydraulic manifold 3D printed

This is a 3D hydraulic valve block printed in stainless steel for controlling a single-acting cylinder.

 

The traditional hydraulic block has been redesigned with a different and innovative design approach: put the valves in which it is necessary and connect the valves, as you wish, with the main objective to reduce the mass of the component whilst retaining its robustness.

 

Additive manufacturing is highly suited for the design and manufacture of manifolds due to its ability to build internal features and passageways. Our internal channels of the valve block are optimized to a better flow and space savings, while the potential for leakage is removed because auxiliary drillings are no longer necessary.

 

This 3D printed hydraulic block greatly meets the specific

needs of customer.

3D printing advantages:

 

  • Freedom to design
  • Possibility to produce complex geometries
  • High customization
  • Space saving
Additive manufacturing in Hydraulics

HEAT EXCHANGER

This is a 3D printed Heat Exchanger for water-oil made with Additive Manufacturing in Aluminum (AlSi10Mg).

 

It exchange 12 kW and compared to the conventional Heat Exchanger its size is 1/5.

 

The weight is 85% less than the traditional product. With Additive Manufacturing it is possible to combine multiple parts into one.

3D printing advantages:

 

  • High performances in small size
  • Possibility to combine  multiple parts into one
  • 1/5 size dimension
  • 85% weight reduction

from

Traditional production

10,8 kg

to

Metal 3D printing

1,5 kg

HIGH PRESSURE HYDRAULIC MANIFOLD

This 3D printed hydraulic manifold is designed for high pressure (700 bar).

The material is Aluminum (AlSi10Mg) and compared to the conventional manifold the weight reduction is 75%.

3D printing advantages:

 

  • Optimized performances, thanks to curved channels and no more 90 degrees intersection angles
  • Good material properties (similar to metal bars)
  • Lightweight solutions
  • High pressure resistance (700 bar)

from

Traditional production

5 kg

to

Metal 3D printing

1,3 kg

BANKABLE HYDRAULIC MANIFOLD

With metal 3D printing the manifold can be multiplied providing more functionalities.

The modular conception of valves allows to easy tailor the blocks to specific requirements.

3D printing advantages:

 

  • Feasibility of geometric forms impossible with traditional machine
  • Ability to combine multiple parts into one
  • Possible better performance than the traditional manufacturing

 

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