OLA

Case Study: Complex Fluid Manifold

316L Stainless Steel | Selective Laser Melting (SLM)

Metal 3D Printing Application

1. Background

A process equipment manufacturer needed to replace a multi-piece welded fluid distribution manifold used in chemical dosing skids. The legacy design suffered from chronic leak points at flange joints, long lead times, and flow turbulence caused by sharp 90° internal channels. Conventional CNC machining could not produce the complex internal flow paths required for optimal performance, and casting required expensive tooling with a 12-week lead time.

2. The Challenge

Design requirements included:

· 6 parallel outlet channels feeding a single inlet header

· Internal flow path optimized to reduce turbulence and pressure drop

· Flange-integrated base with bolt-hole pattern for direct skid mounting

· Corrosion resistance to acidic process media

· Deliverable in under 4 weeks, with zero tooling investment

3. The Solution

The manifold was redesigned as a single monolithic part using topology optimization and manufactured by Selective Laser Melting (SLM) in 316L stainless steel. Internal flow channels were re-engineered with smooth, gradually curving transitions that would be impossible to produce by machining. The flange and main body were consolidated into one piece, eliminating all welded joints and potential leak paths.

 

Figure 1: SLM-printed 316L manifold — 6-outlet vertical configuration with integrated flange

4. The Result

· 70% reduction — in assembly time (1 part vs. 7)

· Zero leak points — fully monolithic construction

· 30% lower pressure drop — thanks to optimized internal geometry

· Lead time: 3 weeks — from CAD to finished part

· ~40% cost savings — vs. cast + machined equivalent at low volume

· Full certification — 316L / ASTM A276, RoHS & REACH compliant

“The redesigned manifold is now in serial production, delivering measurable efficiency gains for the end user's dosing system.”

 

Figure 2: SLM-printed 316L manifold — curved organic outlet geometry, monolithic flange base

 

Material: 316L Stainless Steel  |  Process: SLM / Metal 3D Printing  |  Industry: Process Equipment