Complex Valve Block Consolidated into Single 6.3kg Part Reducing Footprint by 73%

Client & Context: 

This project focused on a Steering Gear Hydraulic Valve Block with integrated heat exchanger traditionally a heavy, complex assembly prone to leakage and requiring significant installation effort. 

The Challenge: 

The conventional design combined a large machined valve block and a separate off-the-shelf cooler, joined by tubes and connectors. 

• Multiple plugs and joints added failure risks and cost. 

• Assembly required a crane due to its 45kg weight. 

• The narrow tubing increased flow resistance, reducing system efficiency. 

The Solution: 

Using Laser Powder Bed Fusion (LPBF) and Stainless Steel 316L, the component was completely redesigned and consolidated into a single part. 

• Internal flow paths were optimized for reduced pressure loss and improved thermal performance. 

• Sealing surfaces and connectors were eliminated through smart part consolidation. 

The Results: 

• 73% reduction in system footprint 

• 85% weight reduction: from 45kg to 6.3kg 

• 14 fewer potential leakage points 

• No crane required for installation—can be handled by one crew member 

• Lead time: just 3 weeks 

Why It Matters: 

This project demonstrates how on-demand manufacturing enables more than just faster lead times—it unlocks smarter, lighter, and more efficient component designs. For OEMs, this means cost savings, easier maintenance, and improved reliability across vessel systems. 

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