A conventional pressure valve consists of a solid block of material in which internal channels are created with straight and circular drillings. Afterwards, some auxiliary drillings need to be plugged, which creates the risk of leakage. The VTT Technical Research Centre of Finland, the largest multidisciplinary research organization in Northern Europe, decided to explore the possibilities of 3D Printing to create the ideal hydraulic valve—lighter, with a better fluid flow and with minimal risk of leakage—for their customer Nurmi Cylinders. VTT relied on Materialise software Materialise 3-matic to enhance the design optimized with Altair software.Altair’s OptiStruct was used for the topology optimization and to define the optimal placement of material within the design space, while Materialise 3-matic was needed to smooth the resulting mesh and turn it into the printable shape.
No Laborious Redesign to CAD
Many companies use topology optimization software and then spend much time and effort to redesign the optimized model in CAD. In fact, this is not the fastest way to success. VTT enhanced the hydraulic valve in STL in Materialise 3-matic, positioned the part, created support structures in data preparation software Materialise Magics, and sent the file directly to the SLM metal printing machine. This clever action saved VTT an impressive amount of time. The SLM Build Processor smoothly communicated the data to the printer, divided the part in slices and created the appropriate laser scan strategy.
This was an ideal project to use 3D Printing, since it was a bionic design produced in small series. The final part is excellent in terms of weight, performance, costs and time investment. The printed end-part only weighs 600g compared to the original 2.5kg, or an impressive weight reduction of 76%. The smooth transitions between the internal channels improve the flow of fluids, and since no auxiliary drillings were necessary the risk of leakage is greatly reduced. Finally, VTT saved a lot of time since they didn’t have to go through the difficult job of directly redesigning the topology data to CAD. They avoided this burdensome step by working immediately on the topology data with Materialise 3-matic.
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All images courtesy of VTT and Nurmi Cylinders Oy.