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How to Avoid Pressure Drop Problems in Hydraulic Manifolds

How to Avoid Pressure Drop Problems in Hydraulic Manifolds

Smart design choices that reduce energy loss and improve system efficiency

Residential mobility assistance systems—like lifts and home accessibility platforms—require quiet, efficient hydraulic performance. Because these systems use screw pumps and operate at lower pressures to minimize noise, managing pressure drop is critical to ensuring smooth, reliable motion.

But pressure drop isn't just a performance issue—it's also a cost and longevity concern. Poor design can result in energy waste, premature wear, and even system failure. 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. When those pressure drops add up, the system may not deliver enough pressure to actuators—causing poor performance or incomplete movement.

Every psi of pressure drop (ΔP) represents wasted horsepower. That wasted horsepower turns into heat. That heat then needs to be removed—usually via a cooling system—which requires more energy. It's a compounding cycle of wasted energy, making pressure drop a critical factor in performance, overall system efficiency, and energy cost.

Key Point: Every psi of pressure drop wastes horsepower, creates heat and drives up energy costs—a cascading cycle of inefficiency.

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

Component Sizing and Passageway Design Matter

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

But it's not just about the components—it's about the flow paths inside the manifold. Traditional manifolds often feature 90-degree turns or sudden changes in diameter, which cause energy loss and flow disruption.

Tip: Minimize sharp turns and sudden diameter shifts. Smooth transitions keep flow velocity consistent and reduce Delta P.

Sand-Cast Manifolds with Flow-Optimized Geometry

Additive manufacturing is a game-changer for hydraulic manifolds. The Bosch Rexroth manifolds we offer use 3D sand core printing to produce flow-optimized internal passages and integrated functions—all based on CFD (Computational Fluid Dynamics) 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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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.