Introduction

Precision is essential in flow measurement technology. Flow probes enable simple and accurate detection of fluid flows. Using micro laser sintering, the components are flexibly adapted to the respective application and manufactured as required. Size and shape can be individually adapted to different areas of application.

What really matters.

In order to increase the efficiency of products through which air flows - such as aircraft engines, compressors or vehicles - flow parameters of fluids (e.g. air or liquids) such as velocity, pressure and flow angle are recorded using measuring probes. Based on the evaluated measurement data, geometries can be optimized or specifically controlled during operation.

How the flow probe works

The shape of the probes - for example with a diameter from 1 mm - can be easily adapted to the customer's requirements. Based on the Bernoulli effect, the Vectoflow measuring probes enable simple and precise determination of the pressure, speed and flow angle of fluid flows. To do this, the pressure distribution at the tip of the probe is evaluated, allowing the flow parameters to be derived precisely. The more holes there are at the tip of the probe, the greater the measurement accuracy that can be achieved and the larger the angle range that can be measured.

These advantages also apply to high-frequency and high-temperature probes. Integration into complete systems makes it possible to use them in UAVs or wind turbines, for example.

Conventionally manufactured measuring probes

Measuring probes are manufactured conventionally using various production technologies. The smaller the dimensions, the more complex and complicated the assembly of the probes becomes. Miniaturization also reduces the stability of the components, which has a negative impact on their service life. The solutions currently available often lack robustness, user-friendliness and geometric flexibility.

Additive thinking

Vectoflow specializes in the development and design of complex flow measurement probes. Vectoflow recognized the potential of additive manufacturing right from the start and uses it consistently. This results in designs that are ideally tailored to the respective field of application and can be manufactured quickly and without subsequent assembly from a single component. Depending on the size of the probe and the given requirements, different additive manufacturing technologies are used.

Vectoflow relies on the additive manufacturing technology "Micro Laser Sintering" from 3D MicroPrint GmbH for applications in the smallest installation space with maximum resilience. Compared to other available processes, this technology offers significantly higher detail resolution for intricate structures as well as significantly lower surface roughness after the construction process - which considerably reduces post-processing costs.

New probe design ensures additive manufacturability

When designing a component, the possibilities and limitations of the respective manufacturing technology must always be taken into account. After the first exchange between 3D MicroPrint and Vectoflow, it was already clear that the original model was not suitable for additive manufacturing and that a redesign would lead to the desired result. Particular attention was paid to the channel geometries inside the probe, the probe neck and the support structure. In several iterations of design optimization, additive manufacturing and test procedures, both the depowdering of the channels and the structural stability of the filigree internal structures were significantly improved.

Flow probes from Vectoflow - manufactured by 3D MicroPrint

The measuring probes were manufactured using the Micro Laser Sintering System DMP50GP from 3D MicroPrint and then separated from the build platform using wire cutting. In order to minimize flow-related influences due to surface roughness, the probes were specifically reworked and the surfaces optimized accordingly.

Micro laser sintering with the 3D printing systems from 3D MicroPrint opens up completely new design possibilities in component design. This technology enables innovative applications in microfluidics, flow-optimized geometries and the integration of additional functions - and therefore completely new potential for our customers. The use of the micro laser sintering process achieves outstanding mechanical properties and an exceptionally high level of detail in the filigree flow probes. As the components are manufactured from a single piece, assembly times are eliminated - and the end product is robust and durable, even under demanding operating conditions.