Abstract
This paper explores the critical aspects of designing and manufacturing hydraulic manifold blocks using advanced additive manufacturing techniques. The study focuses on how 3D printing technologies, including stereolithography (SLA), digital light processing (DLP), continuous liquid interface production (CLIP) and direct metal printing (DMP), can influence the manifold performance, the structural integrity and the fluid dynamics. The research highlights the advantages of these technologies in reducing material waste, enabling lightweight structures, and allowing for the construction of complex internal geometries that can improve the circulation of the fluid. By presenting results of Computational Fluid Dynamics (CFD) simulations, this paper demonstrates how 3D-printed manifolds can have reduced pressure losses comparing to the traditionally machined design. Resin-based materials such as epoxy, acrylate, and nanocomposites have good mechanical properties, which make them appropriate for high-pressure applications. The paper also provides information on modern technologies such as post-processing by thermal treatment and hybrid manufacturing. Future research directions regarding smart manifold integration and industrial adoption of 3D-printed hydraulic systems are discussed.