OLA

Case Study: Radial Spray Diffuser with Central Dome

316L Stainless Steel | SLM | Spray Nozzle Header with Radial Flow Channels

Metal 3D Printing Application

1. Background

A process cooling system was using a cast + drilled spray header to distribute water over a packed bed. The cast body had to be drilled and tapped for 16 individual spray nozzles, which made the header expensive, leak-prone at the threaded fittings, and impossible to clean without disassembly. The customer needed a monolithic spray header with calibrated radial outlets, a self-cleaning internal geometry, and a single flange connection to the supply line.

2. The Challenge

Design requirements included:

· 16 calibrated radial spray outlets with uniform flow resistance

· Monolithic body — no threaded fittings, no gaskets on the flow path

· Self-cleaning internal flow geometry to reduce fouling

· 8-bolt flange base compatible with the existing supply line

· 316L stainless steel for corrosion resistance in process water / chemical service

3. The Solution

The spray header was redesigned as a single monolithic part with a central dome inlet and 16 radial channels that distribute flow to calibrated outlet ports, manufactured by Selective Laser Melting (SLM) in 316L stainless steel. The internal flow channels were designed with smooth, gradually diverging transitions to ensure even flow distribution across all 16 outlets without the need for individual calibration. The dome and the radial arms were printed as one continuous body, with the 8-bolt flange base machined to match the existing supply connection. The smooth internal passages also resist fouling and can be cleaned in place without disassembly.

 

Figure 1: SLM-printed 316L radial spray diffuser — central dome inlet, 16 radial flow channels, 8-bolt flange base, fully monolithic

4. The Result

· 16 calibrated outlets — uniform flow distribution within ±5% across all ports

· Monolithic body — no threaded fittings, no gaskets on the flow path

· Self-cleaning geometry — smooth diverging passages resist fouling

· Drop-in flange base — 8-bolt pattern, matches existing supply line

· 40% weight reduction — vs. cast + drilled legacy header

· Lead time: 3 weeks — from CAD to machined, calibrated header

“We replaced 16 threaded nozzles and 16 gaskets with a single monolithic header. Cleaning time dropped by 80% and the spray pattern is now perfectly uniform.”

 

Material: 316L Stainless Steel  |  Process: SLM / Metal 3D Printing  |  Application: Radial Spray Diffuser Header