Novel filter designs that deliver filtration benefits produced by metal additive manufacturing

Optimisation of fluid flow through a filter and minimising turbulence and pressure drop can lead to a more efficient filtration system. Traditionally, metal filters have been manufactured using perforated plate, mesh and wedge wire. Additive Manufacturing (AM) technology can be used to produce filters whose geometries cannot be manufactured using more conventional manufacturing technologies. Three novel filter geometries were designed for fabrication using AM to reflect three traditional filter types. A filter design, with holes in-line to the direction of fluid flow, which can be directly compared to perforated plate, was produced using AM technology with 316L Stainless Steel (SS316L) as the build material. When compared to conventional filters of similar aperture size, the pressure drop across the AM filter with increasing flow rates was significantly less compared to the conventionally manufactured filter. Thus, less pumping energy is required for the in-line hole AM filter. The AM filter designed to be representative of a mesh-based filter, was created as a single part with an integrated support and filter section. This filter has a significantly increased open area and increased flow rate compared to its comparable mesh filter. The AM filter representing that fabricated from wedge wire, overcomes conventional fabrication issues and is an advance towards leaner manufacturing. AM technology has enabled the production of innovative, geometrically complex, 3D filter designs that have significant increases in filtration efficiency. Industrial application of these filters will have a positive impact in reducing the carbon footprint of end users.