Method for producing servo valve manifolds and manifold with curvilinear flow gallery of single piece construction

1. A method for producing a servo valve manifold, the method comprising:

forming a manifold through additive manufacturing to have a one piece, monolithic body, forming a cylindrical cavity defined in the body to contain a spool, and forming a first flow gallery and a second flow gallery each defined in the body during the additive manufacturing to have a length and a cross section that varies in shape along at least a portion of said length, and each gallery being defined in the body during the additive manufacturing to follow a curvilinear path comprising a nonlinear path in three-dimensional space;

wherein each gallery curves within the body around the cylindrical cavity from a first location within the body and spaced apart from the cylindrical cavity to a second location within the body and spaced apart from the cylindrical cavity, the first and second locations of each one of said galleries being spaced apart from each other (i) around a circumference of the cylindrical cavity and (ii) along a length of the cylindrical cavity, each gallery thereby defining a flow path along a circumferential direction with respect to the central axis of the cylindrical cavity, and

wherein the first and second flow galleries are intertwined.

2. A method for producing a manifold according to claim 1 , further comprising the step of: forming at least one flow control feature as part of the single piece manifold during the additive manufacturing process.

3. A method for producing a manifold according to claim 1 , wherein each of said flow galleries has an end at a fluid port located on an inner surface of the cavity.

4. A manifold according to claim 1 , wherein the first and second locations are spaced apart by an angle of at least 45 degrees around the circumference of the cylindrical cavity.

5. A servo valve manifold, comprising:

a single piece, monolithic body having defined therein a cylindrical cavity having a circumference and containing a spool, and a first flow gallery and a second flow gallery each defined in the body and following a curvilinear path comprising a nonlinear path in three-dimensional space within the manifold;

wherein each gallery curves within the body around the cylindrical cavity from a first location spaced apart from the cylindrical cavity to a second location spaced apart from the cylindrical cavity, the first and second locations of each one of said galleries being spaced apart from each other (i) around a circumference of the cylindrical cavity and (ii) along a length of the cylindrical cavity each gallery thereby defining a flow path along a circumferential direction with respect to the central axis of the cylindrical cavity, and

wherein the first and second flow galleries are intertwined.

6. A manifold according to claim 5 , wherein each of said flow galleries has a variable cross-section.

7. A manifold according to claim 5 , in which the single piece manifold incorporates a flow control feature.

8. A manifold according to claim 5 , wherein each of said flow galleries has a length and the curvature of each flow gallery varies along a majority of the length of the flow gallery.

9. A servo valve manifold according to claim 5 , wherein each of said flow galleries has a length and a cross section that varies in shape along at least a portion of the length.

10. A servo valve manifold according to claim 5 , wherein each of said flow galleries has an end at a fluid port located on an inner surface of the cavity.

11. A manifold according to claim 5 , wherein the first and second locations are spaced apart by an angle of at least 45 degrees around the circumference of the cylindrical cavity.