Numerical Optimization of Internal Geometry for Additively Manufactured Hydraulic Manifolds

Authors

Jan Bartolj
University of Ljubljana, Faculty of Mechanical Engineering
Katharina Schmitz
RWTH Aachen University, Institute for Fluid Power Drives and Systems
https://orcid.org/0000-0002-1454-8267
Nikola Vukašinović
University of Ljubljana, Faculty of Mechanical Engineering
https://orcid.org/0000-0003-4708-0469
Franc Majdič
University of Ljubljana, Faculty of Mechanical Engineering
https://orcid.org/0000-0002-6053-9206

Synopsis

This study presents a novel approach for the design and optimisation of hydraulic manifolds with self-supporting geometries that are compatible with additive manufacturing. Conventional manifolds with a circular cross-section often require complex post-processing as the internal channels are not supported. In this work, configurations of cross-sectional shapes that do not require support structures are investigated. A parametric optimisation and an adjoint gradient algorithm strategy were implemented to refine the cross-sectional geometry of the internal channels with the aim of minimising pressure loss while ensuring manufacturability. Use of CFD simulations to analyse the flow behaviour and pressure losses for different design variants. The integration of self-supporting features not only improves flow efficiency but also realises the full potential of AM by reducing manufacturing time and post-processing requirements. This research contributes to the development of more efficient, production-ready hydraulic systems through simulation-based design methods that take cross-sectional geometry into account.

Author Biographies

Jan Bartolj, University of Ljubljana, Faculty of Mechanical Engineering

Ljubljana, Slovenia. E-mail: jan.bartolj@fs.uni-lj.si

Katharina Schmitz, RWTH Aachen University, Institute for Fluid Power Drives and Systems

Aachen, Germany. E-mail: Katharina.Schmitz@ifas.rwth-aachen.de

Nikola Vukašinović, University of Ljubljana, Faculty of Mechanical Engineering

Ljubljana, Slovenia. E-mail: nikola.vukasinovic@fs.uni-lj.si

Franc Majdič, University of Ljubljana, Faculty of Mechanical Engineering

Ljubljana, Slovenia. E-mail: franc.majdic@fs.uni-lj.si

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Published

September 16, 2025

License

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

How to Cite

Bartolj, J., Schmitz, K., Vukašinović, N., & Majdič, F. (2025). Numerical Optimization of Internal Geometry for Additively Manufactured Hydraulic Manifolds. In D. Lovrec & V. Tič (Eds.), & (Ed.), International Conference Fluid Power 2025: Conference Proceedings (Vols. 2025, pp. 31-44). University of Maribor Press. https://doi.org/10.18690/um.fs.7.2025.4