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Avoid Pressure Drop Problems in Hydraulic Manifolds

Avoid Costly Pressure Drop Issues in Hydraulic Manifolds

Smart design choices that reduce energy loss and improve system efficiency

Pressure drop isn't just a performance issue in hydraulic systems; it's a hidden source of wasted energy, excess heat, and premature wear. Every psi of pressure drop represents lost horsepower that turns into heat, requiring even more energy to cool the system. It's a compounding cycle of inefficiency that can quietly erode system performance and your bottom line.

Managing pressure drop becomes even more critical in systems where smooth and quiet operation is essential, such as residential mobility assistance platforms. But whether it's mobile or industrial hydraulics, smarter manifold design can deliver major gains in efficiency, equipment life, and energy savings.

At FSC, we help customers prevent these issues by providing smart component sizing, system design support, and flow-optimized manifold solutions.

Why Pressure Drop Is a Big Deal

Every valve and passage in a hydraulic system introduces resistance, and resistance causes pressure drop. As these pressure drops accumulate, the system may struggle to deliver enough pressure to the actuators, resulting in poor performance or incomplete movement. More critically, every psi of pressure loss represents wasted horsepower that turns into heat, which must be removed. Heat removal is usually accomplished via a cooling system, which requires even more energy. This cascading cycle of inefficiency drives up operating costs and erodes overall system performance and reliability, making pressure drop one of the most critical factors to address in hydraulic design.

Excessive pressure drop also increases internal velocity and turbulence, which can lead to erosion inside the manifold. This shortens equipment life and increases the risk of costly system failures.

Component Sizing and Passageway Design Matter

To keep pressure losses low, start with smart component sizing. Undersized valves and fittings increase resistance and reduce overall system efficiency.

However, component selection is only part of the equation. The design of internal flow paths within the manifold plays a critical role. Traditional manifolds often feature sharp 90-degree turns and sudden changes in diameter, both of which disrupt smooth fluid flow, cause energy loss, and increase pressure drop. Designing manifolds with smooth, gradual transitions helps maintain consistent flow velocity, minimizing turbulence and reducing Delta P across the system.

Sand-Cast Manifolds with Flow-Optimized Geometry

Additive manufacturing is transforming hydraulic manifold design. The Bosch Rexroth manifolds we offer at FSC use 3D sand core printing to produce flow-optimized internal passages, all based on Computational Fluid Dynamics (CFD) simulations.

These advanced manifolds:

  • Minimize pressure drop through smoother, curved flow paths
  • Reduce noise, making them ideal for residential or low-pressure applications
  • Save energy over time—up to 740 kWh annually in some systems
  • Cut CO₂ emissions and reduce total material use by up to one-third
Smarter manifolds don't just save energy—they pay for themselves within a few years.

Partner with FSC to Design Smarter

At FSC, we help customers implement reliable, efficient hydraulics with hands-on engineering expertise and a wide selection of hydraulic solutions, including flow-efficient manifolds. If you're building or upgrading a system where pressure drop is a concern, we're here to help.

Ready to optimize your hydraulic design?

Contact FSC to speak with an expert and explore efficient manifold solutions tailored to your application.

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The FSC Difference 

Solution Minded. Customer Focused.

Your project's success is our mission! FSC is your one-stop shop for mobile and industrial components and systems, partnering with the world's leading brands. Our team of experienced professionals brings a wealth of knowledge to every project, covering mechanical, electrical, pneumatic, and engineering disciplines. We're ready to collaborate and find the perfect solution for your needs.