THE ULTIMATE PLASTIC MANIFOLD & PRODUCT DESIGN GUIDE

TOM ROHLFS & ZACK HORTON

Contributions from Pete Poodiack, Dennis Hansen, & Kelsey Mollick. Edited and designed by Joe Falco

Controlled Fluidics presents an in-depth Plastic Manifold Design Guide, crafted from extensive industry experience. This guide provides valuable information on material selection, bonding methods, channel configurations, and other essential aspects to assist engineers, designers, and teams in developing efficient and reliable fluidic systems and plastic products.

• Getting Started with Manifold Design: Fundamental principles and considerations for initiating a design project.
• Channel Design Ideas: Innovative approaches to designing fluidic channels that enhance performance and manufacturability.
• Threaded Holes: Best practices for incorporating threaded holes into plastic manifolds, ensuring durability and leak prevention.
• Plugging Cross-Drilled Manifolds: Techniques for effectively sealing cross-drilled channels to maintain system integrity.
• Connection Port Options: Overview of various port configurations to facilitate seamless integration with other components.
• Temperature & Mechanical Properties: Insights into how different materials respond to thermal and mechanical stresses.
• Electrical, UV, & Outgassing Properties: Considerations for applications requiring specific electrical insulation, UV resistance, or low outgassing materials.
• Chemical Resistance in Plastic Materials: Guidance on selecting materials based on chemical compatibility requirements.
• Material Options for Plastic Manifolds: Comparison of various plastics suitable for manifold fabrication, including their advantages and limitations.
• Material Colors for Plastic Manifolds: Discussion on color options and their implications for functionality and aesthetics.
• Manufacturing Plastic Manifolds: Detailed look at different manufacturing processes, such as drilling, bonding, and 3D printing.
• Manifold Fabrication Processes: Analysis of fabrication techniques and their suitability for specific design requirements.
• All About Bonding Plastic Manifolds: Exploration of bonding methods, potential defects, and quality assurance practices.
• Surface Finishing and Polishing: Strategies for achieving desired surface finishes to enhance performance and appearance.
• Plastic Lettering Options: Options for incorporating labels and markings into manifold designs.
• Component Assembly on Plastic Manifolds: Guidelines for integrating valves and other components into the manifold assembly.
• Plastic Manifold Handling & Cleaning Guide: Best practices for maintaining and cleaning plastic manifolds to ensure longevity.
• Expert Guidelines for Designing and Manufacturing Superior Plastic Manifolds: Advanced tips and recommendations for optimizing manifold design and production.

Please note that the following guide is intended to provide a general approach to the design of plastic manifolds. Users should undertake appropriate verification of their specific design to ensure suitability for their applications. We don't intent for this guide to confirm a design's fitness for a particular use. All the data contained herein should be used as a reference only.

With that in mind, let's proceed with the basics of manifold design.