This project aims to redesign a lighter hydraulic manifold that maintains the same high pressure performance. The need for lightness and a niche application have led us to choose additive manufacturing technologies. We obtained a weight reduction from 5 kg of the traditional manufactured manifold to 15 kg with metal 3D printing with a weight reduction of over 70%. The material used is Aluminum alloy (Alsi10Mg) which has good mechanical properties combined with low specific weight. The design took into account both the lightness need and the pressure within the channels. Indeed additive manufacturing is particularly suitable for the design of manifolds thanks to its ability to build internal features and passageways improve the shape of internal channels for an optimal flow eliminate the need for auxiliary drillings and reduced potential for leaks.
The 3D printed hydraulic manifold is installed in a portable power unit.