Three-dimensional follow-up layout design approach for lightweight hydraulic passage networks

Additive manufacturing (AM) enables the transformation of conventional bulky hydraulic manifolds into lightweight passage networks, resulting in a significant weight reduction. However, the enhanced design freedom provided by AM also introduces substantial complexity and uncertainty. Efficient and automated design methodologies for lightweight and energy-efficient hydraulic passage networks in complex three-dimensional (3D) spaces remain limited. To address this challenge, an innovative 3D “follow-up” layout design approach is proposed to achieve automatic component arrangement and flow-channel planning for additively manufactured hydraulic passage networks. The proposed method integrates the component layout and flow-channel planning to enable global optimization and enhance design efficiency. The design process comprises two main stages: (1) a rapid iterative layout of cartridge components using a simulated annealing algorithm to minimize the total layout cost while satisfying the design constraints, and (2) 3D flow-channel planning based on the A* algorithm to determine the optimal paths while avoiding obstacles. A case study involving the redesign of a conventional hydraulic manifold validated the effectiveness of the proposed method.