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Through its unique characteristics, additive manufacturing yields great potential for designing fluid components with increased performance characteristics. These potentials in advanced design, functional structure, and manufacturing are not easily realized. Therefore, the present study proposes a holistic development methodology for fluid components with a specific focus on hydraulic manifolds. The methodology aims to lead the designer from the specification of the task, through a step-by-step embodied design, to a technical and economic evaluation of the optimized, first-time manufactured part. A case study applies the proposed methodology to a part of a rail-vehicle braking application. Through its application, a significant reduction in weight, size, as well as significant contributions to the company’s AM strategy can be assigned to the part. At the same time, increased direct manufacturing costs are identified. Based on the increased performance characteristics of the resulting design and the holistic foundation of the subsequent economic decisions, a satisfying efficiency can be allocated to the proposed methodology.

Development Workflow for Manifolds and Fluid Components Based on Laser Powder Bed Fusion