A novel design model of flow channel paths for additive manufacturing

Purpose This paper aims to propose a method for automatic design of additive manufacturing (AM) flow channel paths driven by path length and pressure loss. The research focuses on the automatic design of channel paths, intending to achieve the shortest flow channel length or minimum pressure loss and improve the design efficiency of AM parts. Design/methodology/approach The initial layout of the flow channels is redesigned to consider the channels print supports. Boundary conditions and constraints are defined according to the redesigned channels layout, and the equation consisting of channel length and pressure loss is used as the objective function. Then the path planning simulation is performed based on particle swarm algorithm. The proposed method describes the path of flow channels using spline cures. The spline curve is controlled by particle (one particle represents a path), and the particle is randomly generated within the design space. After the path planning simulation is completed, the generated paths are used to create 3D parts. Findings Case study 1 demonstrates the automatic design of hydraulic spool valve. Compared to conventional spool valve, the pressure loss was reduced by 86% and the mass was reduced by 83%. The design results of case study 2 indicate that this approach is able to find the shortest channel path with lower computational cost. Originality/value The automatic design method of flow channel paths driven by path length and pressure loss presented in this paper provides a novel solution for the creation of AM flow components.