Automated layout optimization for hybrid additively manufactured hydraulic manifolds

Purpose Hydraulic manifolds are traditionally manufactured by milling, which can result in suboptimal performance and weight. Additive manufacturing (AM) offers the potential to improve performance, but the high production costs and the need for extensive postprocessing are major challenges. The hybrid manufacturing approach provides the opportunity to combine the advantages of milling and AM while overcoming their disadvantages. This study aims to highlight the potential of this approach by exploring three design approaches for hybrid AM manifolds. However, to enable these hybrid designs, computational support tools for the manual and time-consuming layout process are essential. Design/methodology/approach This paper presents specialized layout optimization algorithms tailored to three design approaches for hybrid AM manifolds. A rule-based automation approach is employed in conjunction with a genetic algorithm. Findings The efficacy of these algorithms is demonstrated through a case study. The resulting designs are manufactured, evaluated and compared based on performance- and cost-related criteria. The study results demonstrate the potential of hybrid AM compared to parts that are either fully milled or fully additively manufactured, while highlighting the distinct differences between the three hybrid design approaches. Originality/value Existing placement algorithms used in solving geometric packing problems fall short of meeting the application-specific requirements of designing hybrid AM manifolds. This study addresses this gap by providing algorithms for automating the layout process in hybrid manufacturing, ultimately advancing the development of more efficient and cost-effective hydraulic systems.