In this case study you can see that the component is originally a solid block where two pipes, carrying fluids, merge into one larger pipe which exits the block at right angle to the original direction. Traditionally, in order to create this component, you would have to drill two holes into the top of the block in such a way as to meet another hole that was drilled into the side of the block. Where the pipes meet in the middle of the block would then be a point of resistance as the flow of fluid would be interrupted by the sharp angle change between the pipes. By building the pipe design into the component, a more continuous pipe construction can be created where a uniform cross section is maintain between the two smaller pipes and the one larger pipe and a smoothly curving junction can be created the limits any unwanted interruption to the fluid flow.

In addition to the task of designing the pipes, this conceptual block had two further requirements; those of withstanding a fictional asymmetric complex loading from the top surface of the block and the need to support the under surface of the top plate of the block. The underneath of the larger pipe (and the junction to some extend) also need to be supported).

The images above demonstrate the design process and resulting lattice design. The part was then built in stainless steel on the EOS M270.