We are one of the leading manufacturers and exporters of Aluminium Manifolds and Aluminium Manifold Blocks from India. We have been supplying precision aluminum hydraulic manifolds and pneumatic manifold blocks to the world market for many decades. Our state-of-the-art manufacturing facility specializes in producing high-precision custom aluminum manifold systems using advanced computer numerical control machining technology, multi-axis CNC drilling centers, deep hole drilling equipment, and sophisticated manifold design software. With over three decades of global experience in aluminum manifold manufacturing, we serve diverse industries including hydraulic system aluminum manifolds, pneumatic control aluminum manifold blocks, industrial fluid power aluminum manifolds, mobile hydraulic aluminum manifolds, oil and gas aluminum manifold systems, marine hydraulic aluminum manifolds, aerospace fluid control aluminum manifolds, and manufacturing automation aluminum pneumatic manifolds. Our expertise encompasses working with various aluminum alloys including 6061-T6 aluminum manifold blocks offering excellent pressure rating and corrosion resistance, 7075-T6 aluminum high-pressure manifolds for demanding applications, 5052 aluminum marine-grade manifolds, and 2024 aluminum aerospace manifold systems. We manufacture aluminum manifolds ranging from compact single-station pneumatic manifolds to complex multi-circuit hydraulic manifold blocks with dozens of intersecting passages, all maintaining tight tolerances and superior surface finish for leak-free performance.
Our advanced manufacturing capabilities in producing precision aluminum hydraulic manifolds extend across multiple machining disciplines including CNC vertical machining centers for manifold block face machining, horizontal machining centers for complex multi-sided manifold drilling, deep hole drilling equipment for internal passages up to 500mm depth, gun drilling machines for precise straight hole boring, and cross-hole drilling capabilities for intersecting passage creation. Our engineering team possesses deep technical knowledge of fluid power system design, aluminum manifold passage optimization, pressure drop calculations, and flow rate analysis ensuring every aluminum manifold block meets customer specifications. Our quality management system complies with ISO 9001:2015 standards, ISO 4401 valve mounting interface specifications, ISO 5781 port dimensions, and NFPA fluid power standards. We maintain complete traceability of aluminum raw material certificates, detailed machining process documentation, pressure test records, and material test reports for every aluminum manifold block produced. Our customers across North America, European Union countries, United Kingdom, Australia, Middle East regions, and Southeast Asian markets trust our aluminum manifold expertise for their critical fluid power applications.
Aluminium Manifolds – Hydraulic and Pneumatic Distribution Systems
Aluminium Manifolds represent specialized components designed to distribute hydraulic fluid or compressed air to multiple circuits from common supply source through precision-machined internal passages connecting various ports. These aluminum hydraulic manifolds are manufactured from high-grade aluminum alloys providing structural integrity under operating pressures while maintaining lighter weight compared to traditional steel manifolds. Aluminum manifolds find extensive applications in mobile hydraulic systems for construction equipment, agricultural machinery hydraulic circuits, material handling equipment, industrial press hydraulic controls, injection molding machine systems, machine tool hydraulic power units, marine vessel hydraulic steering, and pneumatic automation control for manufacturing lines. The design requires careful consideration of passage routing to minimize pressure drops, adequate wall thickness between passages, proper port sizing for flow requirements, standardized mounting patterns for valve installation, and thermal expansion considerations.
Our aluminum manifold design and manufacturing services include engineering consultation for manifold layout optimization, CAD modeling, computational fluid dynamics analysis for passage design validation, finite element analysis for stress evaluation, manufacturing process planning, CNC programming for complex drilling sequences, and prototype development with pressure testing validation. We accommodate aluminum manifold sizes ranging from compact blocks measuring 50mm x 50mm x 30mm for pneumatic applications to large hydraulic manifold blocks exceeding 600mm x 400mm x 200mm with multiple valve stations. Material specifications conform to ASTM B211, ASTM B221, and international standards including EN AW designations, JIS specifications, and GB/T standards. Aluminum manifolds typically operate at working pressures from 10 bar for low-pressure pneumatic systems to 350 bar for high-pressure hydraulic applications. Surface finish for internal passages ranges from 1.6 Ra for critical flow paths to 3.2 Ra for general passages. The lead time for custom aluminum manifold blocks typically ranges from four to six weeks depending on manifold complexity, number of passages, valve station requirements, and testing specifications.
Aluminium Manifold Blocks – Multi-Station Valve Mounting Platforms
Aluminium Manifold Blocks represent the rectangular or custom-shaped aluminum components serving as mounting platforms for multiple hydraulic or pneumatic valves with internal passages interconnecting valve ports to create complete fluid power control circuits. These precision aluminum manifold blocks are manufactured to accommodate standardized valve mounting patterns including ISO 4401 for hydraulic directional control valves, ISO 5781 for valve port connections, CETOP standards for European valve interfaces, NFPA standards for American fluid power applications, and custom valve mounting patterns. Aluminum manifold blocks provide numerous advantages including consolidated packaging reducing system space, elimination of external piping and associated leak points, cleaner installation appearance, reduced assembly time, easier troubleshooting through organized valve layout, and flexibility for system modification. Common configurations include single-station manifolds, multi-station linear manifolds with valves arranged in row, parallel circuit manifolds with independent flow paths, series circuit manifolds for sequential operations, and complex integrated manifolds combining multiple hydraulic functions.
The manufacturing process for precision aluminum manifold blocks begins with aluminum bar stock selection, followed by face milling operations, precision drilling of mounting bolt patterns, deep hole drilling of primary supply and return passages using specialized gun drills, cross-drilling operations creating intersecting passages, secondary passage drilling for circuit connections, thread tapping or milling for port connections, cavity machining for cartridge valve installations, passage plugging using threaded plugs with sealant, deburring, cleaning, pressure testing to verify passage integrity, and optional anodizing for corrosion protection. Our aluminum manifold block capabilities include passage diameters from 3mm for pilot circuits to 40mm for main flow passages, passage depths up to 500mm, passage tolerances of ±0.05mm for critical alignments, thread specifications from M5 to M30, surface flatness on valve mounting surfaces to 0.02mm per 100mm, and port spacing accuracy within ±0.05mm. Standard aluminum manifold block working pressures range from 210 bar for 6061-T6 aluminum to 350 bar for high-strength aluminum alloys.
Aluminum Alloy Grades for Manifold Applications
Aluminum Alloy Material Specifications and Standards for Manifolds
| Aluminum Alloy | International Designation | Key Properties | Typical Applications | Standards |
|---|---|---|---|---|
| 6061-T6 Aluminum | EN AW-6061, JIS A6061, GB 6A02 | Excellent mechanical properties, corrosion resistance, pressure rating to 210 bar | General hydraulic manifolds, pneumatic manifolds, mobile equipment | ASTM B211, BS EN 755-2, DIN EN 755-2, JIS H4040, IS 733 |
| 7075-T6 Aluminum | EN AW-7075, JIS A7075, GB 7A04 | High strength, aerospace grade, pressure rating to 350 bar | High-pressure hydraulic manifolds, aerospace, heavy equipment | ASTM B211, AMS 4123, DIN EN 755-2, JIS H4040, BS L95 |
| 5052-H32 Aluminum | EN AW-5052, JIS A5052, GB 5A02 | Excellent corrosion resistance, marine grade | Marine hydraulic manifolds, offshore equipment, coastal applications | ASTM B209, BS EN 485-2, DIN EN 485-2, JIS H4000, IS 737 |
| 6082-T6 Aluminum | EN AW-6082, JIS A6082 | Structural strength, good corrosion resistance | Industrial hydraulic manifolds, machine tool applications | BS EN 755-2, DIN EN 755-2, ISO AlSi1MgMn |
| 2024-T3 Aluminum | EN AW-2024, JIS A2024, GB 2A12 | High strength, aerospace applications | Aerospace hydraulic manifolds, aircraft ground support, defense | ASTM B211, AMS 4120, BS L96, DIN EN 755-2, IS 736 |
Aluminum Manifold Material Properties Comparison
| Property | 6061-T6 | 7075-T6 | 5052-H32 | 6082-T6 | 2024-T3 |
|---|---|---|---|---|---|
| Tensile Strength (MPa) | 310 | 572 | 228 | 310 | 483 |
| Yield Strength (MPa) | 276 | 503 | 193 | 255 | 345 |
| Recommended Working Pressure (bar) | 210 | 350 | 150 | 200 | 280 |
| Corrosion Resistance | Excellent | Fair | Excellent | Excellent | Poor |
| Machinability Rating | Good (4/5) | Fair (3/5) | Fair (3/5) | Good (4/5) | Good (4/5) |
| Weight Advantage vs Steel | 65% lighter | 65% lighter | 65% lighter | 65% lighter | 65% lighter |
Manufacturing Processes and Technology
Our precision aluminum manifold manufacturing facility employs specialized machining processes including CNC vertical machining centers with multiple-spindle drilling heads, horizontal machining centers with indexing rotary tables enabling four-sided manifold machining, dedicated deep hole drilling machines using gun drill technology for passages up to 500mm depth, cross-hole drilling capabilities with precision indexing, honing operations for critical internal diameters, thread milling for accurate thread generation, and surface grinding for flatness on valve mounting surfaces. Our facility houses CNC machining centers accommodating manifold blocks up to 1200mm x 800mm, spindle power ranging from 15kW to 40kW, through-spindle coolant delivery at pressures up to 70 bar, and automatic tool changers with capacity for 60+ tools.
Manufacturing Process Flow: Customer specification review → Manifold layout design → CAD modeling and passage routing → Drilling sequence planning → CNC program generation → Material procurement → Face milling → Primary passage drilling → Secondary passage drilling → Cross-hole drilling → Thread tapping/milling → Cavity machining → Passage plugging → Deburring and cleaning → Pressure testing → Surface treatment → Final inspection → Packaging and shipping.
Manifold Passage Specifications and Tolerances
Aluminum Manifold Passage Specifications
| Passage Type | Diameter Range (mm) | Depth Range (mm) | Tolerance | Surface Finish | Application |
|---|---|---|---|---|---|
| Main Supply/Return | 12 – 40 | 50 – 500 | ±0.1mm | 1.6 Ra | Primary flow paths |
| Branch Circuits | 6 – 20 | 30 – 300 | ±0.08mm | 1.6 Ra | Secondary circuits |
| Pilot Passages | 3 – 8 | 20 – 200 | ±0.05mm | 1.6 Ra | Control circuits |
| Drain Passages | 6 – 12 | 30 – 250 | ±0.1mm | 3.2 Ra | Leakage return |
| Cross Drilling | 4 – 25 | 20 – 150 | ±0.08mm | 1.6 Ra | Passage connections |
Manifold Port and Mounting Specifications
| Feature Type | Standard Tolerance | Precision Tolerance | Notes |
|---|---|---|---|
| Port Center Distance | ±0.1mm | ±0.05mm | Critical for valve alignment |
| Port Perpendicularity | 0.05mm/50mm | 0.02mm/50mm | Ensures proper seal |
| Mounting Surface Flatness | 0.03mm/100mm | 0.02mm/100mm | ISO 4401 requirement |
| Thread Depth | ±0.2mm | ±0.1mm | Port connection threads |
| Bolt Hole Position | ±0.1mm | ±0.05mm | Valve mounting bolts |
Surface Treatment and Quality Control
Anodizing Treatment: Type II sulfuric acid anodizing creates protective oxide layer 5-25 microns thick providing excellent corrosion resistance. Clear anodizing preserves natural aluminum appearance, while black anodizing offers aesthetic appeal. Hard anodizing (Type III) produces thicker coating 25-100 microns with enhanced wear resistance. Chromate Conversion Coating: Chemical film treatment provides thin protective layer with minimal dimensional impact. Powder Coating: Organic powder coating provides durable colored finish with excellent corrosion protection. Electroless Nickel Plating: Nickel plating provides uniform coating with excellent corrosion and wear resistance, particularly suitable for marine manifolds.
Pressure Testing: Every aluminum manifold block undergoes comprehensive pressure testing at 1.5 times rated working pressure held for minimum 5 minutes while monitoring for pressure drop. High-pressure manifolds intended for 210 bar working pressure undergo testing at 315 bar minimum. All passages are tested including supply, return, branch circuits, pilot passages, and drain lines. Test results are documented including test pressure, hold time, pressure drop measurements, and inspector certification.
Quality Inspection: Dimensional inspection using coordinate measuring machines verifies port locations, bolt hole positions, and mounting surface flatness. Passage alignment is verified using specialized fixtures. Thread inspection confirms proper thread form and depth. Complete documentation includes first article inspection report, dimensional inspection results, pressure test certification, material certificates, and certificate of conformance.
Industries and Applications
Mobile Hydraulics: Construction equipment aluminum manifolds for excavators and loaders, agricultural machinery hydraulic manifolds, material handling equipment manifolds, and utility vehicle hydraulic control manifolds. Weight savings of 65% compared to steel manifolds improves fuel efficiency.
Industrial Machinery: Machine tool hydraulic manifolds for CNC machining centers, injection molding machine hydraulic control manifolds, metal forming press hydraulic manifolds, and automated assembly line hydraulic manifolds.
Aerospace and Defense: Aircraft hydraulic system manifolds meeting aerospace specifications, ground support equipment hydraulic manifolds, military vehicle hydraulic control manifolds, and UAV hydraulic control systems.
Marine Applications: Marine-grade aluminum manifolds for boat steering systems, yacht hydraulic stabilizer manifolds, offshore platform hydraulic equipment, and ship deck machinery. 5052 aluminum alloy provides excellent saltwater corrosion resistance.
Manufacturing Automation: Pneumatic manifolds for automated assembly lines, air logic control manifolds for packaging equipment, compressed air distribution manifolds, and robot pneumatic control manifolds.
Oil and Gas: Hydraulic manifolds for wellhead control systems, drilling equipment hydraulic manifolds, pipeline valve actuation manifolds, and offshore production platform hydraulic systems.
Performance Specifications
Aluminum Manifold Performance Parameters
| Parameter | Standard Range | High-Performance Range |
|---|---|---|
| Working Pressure | 50 – 210 bar | 210 – 350 bar |
| Proof Pressure | 1.5 x Working | 1.5 x Working |
| Burst Pressure | 4 x Working | 4 x Working |
| Flow Capacity | Up to 200 LPM | Up to 500 LPM |
| Operating Temperature | -20°C to +80°C | -40°C to +120°C |
| Port Size Range | M5 to M30 | Custom sizes available |
| Manifold Weight | 0.5 kg to 50 kg | Up to 150 kg |
| Valve Stations | 1 to 10 stations | Up to 20 stations |
Frequently Asked Questions
Q1: What is the maximum working pressure for aluminum hydraulic manifolds?
Aluminum hydraulic manifolds manufactured from 6061-T6 aluminum alloy typically support working pressures up to 210 bar with appropriate wall thickness and geometry, while high-strength 7075-T6 aluminum manifolds can accommodate working pressures up to 350 bar. Working pressure ratings depend on aluminum alloy selection, manifold geometry including wall thickness, passage diameter and routing, operating temperature, and applied safety factors. Our engineering team performs pressure analysis using finite element methods to verify manifold designs meet required working pressures with minimum 4:1 burst pressure safety factor.
Q2: What valve mounting standards do your aluminum manifolds conform to?
Our aluminum manifolds conform to international valve mounting standards including ISO 4401 for hydraulic directional control valves (NG06, NG10, NG16, NG25, NG32 sizes), ISO 5781 for port and stud end dimensions, CETOP standards for European valve interfaces, NFPA T3.5.1 for American fluid power applications, and custom valve mounting patterns per customer specifications ensuring compatibility with global valve suppliers and seamless integration into existing hydraulic and pneumatic systems.
Q3: What is the typical lead time for custom aluminum manifold blocks?
Standard lead time for custom aluminum manifold blocks is four to six weeks from purchase order confirmation to shipment, accounting for engineering review, material procurement, CNC machining operations, passage drilling, pressure testing, surface treatment if specified, and quality inspection. Expedited production available for urgent requirements within 2-3 weeks depending on manifold complexity, number of passages, and valve station requirements.
Q4: Can you design aluminum manifolds from customer specifications or hand sketches?
Yes, our experienced manifold design team provides comprehensive engineering support including manifold layout consultation, CAD design services creating three-dimensional models from customer specifications or hand sketches, computational fluid dynamics analysis evaluating pressure drop and flow distribution, finite element analysis calculating stress under operating pressure, design for manufacturability review, and prototype development with iterative testing and design refinement to ensure optimal performance.
Q5: How do you verify manifold blocks are leak-free before shipment?
Every manifold undergoes comprehensive pressure testing at 1.5 times rated working pressure using hydraulic oil or water-glycol mixture, held for minimum 5 minutes while monitoring for pressure drop. External surfaces are dried and inspected for oil weepage. All passages including supply, return, branch circuits, pilot passages, and drain lines are tested. Pressure test certification documents test pressure, hold time, and results. Complete documentation includes dimensional inspection reports, pressure test certifications, material certificates, and certificate of conformance.
Why Choose Our Aluminum Manifold Services
Three Decades of Manifold Manufacturing Excellence: With over 30 years of aluminum manifold manufacturing experience serving customers across North America, Europe, Asia, and other international markets, we have developed deep expertise in complex hydraulic and pneumatic manifold design and production.
Advanced Manifold Engineering Support: Our experienced engineering team offers manifold layout consultation, CAD design services, computational fluid dynamics analysis, finite element analysis, design for manufacturability review, material selection guidance, and prototype development with pressure and flow testing validation.
Specialized Deep Hole Drilling Capability: Our dedicated deep hole drilling equipment using gun drill technology enables precision passages up to 500mm depth with straightness deviation under 0.1mm per 100mm length and surface finish better than 1.6 Ra, critical for aluminum manifold internal passage quality.
Comprehensive Pressure Testing Validation: Every aluminum manifold undergoes rigorous pressure testing at 1.5 times rated working pressure with complete documentation, ensuring leak-free performance and passage integrity before shipment.
Competitive Manufacturing Advantage: Manufacturing in India provides cost advantages allowing us to offer aluminum manifold services typically 30-40% lower than North American or European manufacturers without compromising quality standards, with transparent quotations and excellent value proposition.
Complete Material Traceability: Our quality system maintains complete traceability from certified aluminum suppliers through finished manifold delivery, detailed process documentation, pressure test records, dimensional inspection reports, and material certificates.
International Standards Compliance: Our aluminum manifolds conform to ISO 4401 valve mounting interfaces, ISO 5781 port dimensions, NFPA fluid power standards, and CETOP European specifications, ensuring compatibility with global valve suppliers.
Flexibility in Manifold Configuration: We accommodate single-station simple manifolds to complex multi-station integrated manifolds with dozens of passages, custom valve mounting patterns, prototype quantities for development projects, and high-volume production with consistent quality.
Glossary of Technical Terms
Manifold Block: Rectangular or custom-shaped aluminum component with internal passages connecting multiple ports serving as mounting platform for hydraulic or pneumatic valves.
Deep Hole Drilling: Specialized machining process creating holes with depth-to-diameter ratios exceeding 10:1 using gun drill or BTA drilling technology.
Cross-Drilling: Machining operation creating passages that intersect existing passages enabling fluid flow between circuits within manifold block.
Working Pressure: Maximum continuous operating pressure for which manifold is designed and tested, typically expressed in bar or PSI.
Proof Pressure: Test pressure equal to 1.5 times working pressure used to verify manifold integrity without permanent deformation.
ISO 4401: International standard specifying mounting dimensions and port patterns for hydraulic directional control valves.
CETOP: European fluid power standards organization defining valve mounting interfaces widely used in European hydraulic applications.
Gun Drilling: Deep hole drilling process using single-lip cutting tool with internal coolant delivery achieving straight holes.
Passage Alignment: Accuracy of intersecting passage locations critical for proper fluid flow between circuits within manifold block.
Cartridge Valve Cavity: Machined cylindrical cavity in manifold designed to accept screw-in cartridge valve.
Call to Action – Contact Us Today
Ready to discuss your aluminum manifold requirements? Our experienced team is here to help you with precision aluminum hydraulic and pneumatic manifolds for your critical fluid power applications.
Request a Quote: Send us your technical drawings, specifications, and quantity requirements to sales@jambrass.com for a detailed quotation within 24 hours.
Call Us Directly: Speak with our technical sales team at +91-22-43449300 / +91-22-43449323 during business hours (Monday-Saturday, 9:00 AM – 6:00 PM IST) to discuss your manifold requirements.
Visit Our Offices:
Office Address: 1406, 14th Floor, Dalamal Tower, Nariman Point, Mumbai – 400021, Maharashtra, India
Factory Address: Plot 10B, GIDC Industrial Estate, Shanker Tekari, Udyognagar, Jamnagar, Gujarat, India – 361004
Contact Person: Mr. Mehul Vora
Quality Documentation: Request sample certificates of conformance, material test reports, pressure test certifications, and inspection documentation by contacting sales@jambrass.com
Prototype Services: Inquire about our expedited prototype aluminum manifold services delivering samples within 2-3 weeks for your evaluation and testing.
We look forward to partnering with you for your aluminum manifold requirements and demonstrating why customers worldwide trust our precision manifold manufacturing expertise.
