Executive Summary Executive Summary Executive Summary
Marcus Pont, CEO Domin
Consider some of the incredible advancements in technology that have transformed our world over the past seventy years; computers have shrunk from the size of a house to the size of a watch, we have moved from a predominantly analogue world to a digital one, from basic rule-based systems to sophisticated machine learning, and seen huge efficiency gains in everything from car engines to solar panels. Almost all of the technology around us has got smaller, faster, and more efficient.
However, despite being central to almost all the most fundamental industries that build our world, hydraulics have not advanced at the same pace as other technology. Rather unbelievably, they still rely on the same clunky, inefficient products that powered our world in the 1950s.
Essential To Countless Industries
The prevailing approach to motion control, especially in hydraulics, is plagued by inefficiency. While hydraulics are essential to countless industries, their widespread use comes with significant energy waste, hindering progress in system efficiency and optimisation.
Consequently, industries are missing out on the significant value that could be unlocked by adopting more advanced technologies in their operations.
This white paper highlights the inefficiencies of hydraulic systems and examines how a return to first principles, combined with the utilisation of modern tools and methods, can revolutionise motion control. In doing so, we can achieve significant enhancements in performance, efficiency and sustainability, across globally critical industries.
Traditional hydraulic innovations have stagnated for decades, with most systems achieving only 22% efficiency according to Oak Ridge National Laboratories.
This inefficiency results in huge amounts of wasted energy in the EU each year; 4,300 Peta Joules, which is enough to power 85 million homes.
This inefficiency results in huge amounts of wasted energy in the EU each year
Peta Joules
which is enough to power
million homes
4,300 Peta Joules
which is enough to power 85 million homes.
Hydraulics are integral to many industries, powering machinery in manufacturing, aviation, automotive, construction, and mining.
Hydraulic systems are in aircraft where compact but powerful actuation is critical to operate the landing gear, flaps, and other control surfaces. In the automotive industry, hydraulic power steering, brakes, and suspension systems are essential for safe, comfortable and reliable vehicles. Further, in industrial settings, hydraulic systems control huge tools and allow the easy movement of heavy loads in very harsh conditions.
Because they are everywhere, they also require an unbelievable amount of energy. McKinsey recently issued a report called “Preparing for the Imminent Revolution in the Fluid Systems Industry”, and they estimated that:
Protecting Our Resources
As human development continues to advance rapidly, the demand for energy will inevitably increase, serving as a crucial resource to fuel this progress. Being wasteful with energy results in industries losing time, money, and opportunities.
Additionally, we are grappling with the trade-offs that are the result of global industrialisation. We have an incredible opportunity, previously overlooked, for all industries to fundamentally rethink their approach to energy usage.
Utilising modern, cutting-edge technology and combining it with a first-principles approach, we can achieve our goals with greater efficiency and enhanced performance, unlocking possibilities that were once thought unattainable.
The question that we have sought to answer is:
How Technology Progresses
Over the years, humanity has experimented with different materials, technologies and methodologies, to build the world around us. As time has progressed, various versions of these have stuck as the best way to manufacture or design to get the most reliable result. We call these the ‘stable technologies’.
An example of the convergence on a stable technology is mobile phones in the early noughties. They initially varied in size and shape, each functioning in its own way. Now, mobile phones are virtually identical in form and function, and consumers are selecting a phone based on small differentiators. However, over time stable technologies can become stagnant and resistant to change.
Modern tools such as metal 3D printing, advanced motors, sensors and electronics, present a significant opportunity to innovate and overcome the limitations of traditional hydraulic systems. These advancements have the potential to establish the new “stable” technology, shaping the creation of systems for the next 50 to 100 years.
Metal 3D Printing
As a manufacturing tool, metal 3D printing offers the capability to create hydraulic technology optimised in ways that remain impossible using traditional manufacturing methods. Although it is a new technology, it is important to acknowledge that metal 3D printing is still just a manufacturing process, albeit one that can unlock huge benefits.
Doing More With Less
Metal 3D printing eliminates the design-for-manufacturing constraints inherent in subtractive machining, allowing for the creation of lightweight structures through optimised material distribution and the removal of excess material.
This reduces the overall weight of the manufactured product, resulting in improved energy efficiency, which we explored in this blog. Plus, as the nature of metal 3D printing means that only the material that is useful to the final product is printed – there is no unnecessary excess material at the production stage.
vs
Making Things That Were Never Possible Before
Metal 3D printing offers unprecedented design freedom. When we find opportunities that allow us to rethink how we design, we can make things that previously were simply not possible.
This kind of shift can be seen by looking back at the construction of the Iron Bridge in 1779—the world’s first major bridge made from cast iron. Initially, engineers applied traditional designs to this new material, but soon they began to innovate, creating bridges that fully utilised cast iron’s properties.
Similarly, while metal 3D printing is currently being used to improve existing designs, the real potential lies in rethinking products from the ground up. Rather than simply tweaking existing products, we can ask: what if this product was designed from scratch with the freedom metal 3D printing allows?
This approach mirrors the Iron Bridge’s legacy—moving from old designs to new paradigms, demonstrating how new technologies can make what was once unimaginable a reality. The Iron bridge is 30.6 metres long and was a feat of engineering. Today, the Danyang-Kunshan Grand Bridge in China is 164km. It is only through this philosophy of reimagination that this seismic difference could be achieved.
Applying this approach, metal 3D printing enables the creation of intricate curvilinear internal passages, channels, and fluid flow paths that are challenging or impossible to achieve using traditional manufacturing techniques. This enhances the performance and efficiency of hydraulic components, by optimising fluid dynamics and reducing pressure losses.
Similarly, while metal 3D printing is currently being used to improve existing designs, the real potential lies in rethinking products from the ground up. Rather than simply tweaking existing products, we can ask: what if this product was designed from scratch with the freedom metal 3D printing allows?
More flow in a Domin S6 Pro than its cast version counterparts.
Customisation
Advanced Motors
Efficiency and Adaptability
Highly Durable
Advanced Motors
Advanced Motors
Advanced Motors
Metal 3D Printing
As a manufacturing tool, metal 3D printing offers the capability to create hydraulic technology optimised in ways that remain impossible using traditional manufacturing methods.
Although it is a new technology, it is important to acknowledge that metal 3D printing is still just a manufacturing process, albeit one that can unlock huge benefits.
Doing More With Less
Metal 3D printing eliminates the design-for-manufacturing constraints inherent in subtractive machining, allowing for the creation of lightweight structures through optimised material distribution and the removal of excess material.
This reduces the overall weight of the manufactured product, resulting in improved energy efficiency, which we explored in this blog. Plus, as the nature of metal 3D printing means that only the material that is useful to the final product is printed – there is no unnecessary excess material at the production stage.
How much material is wasted during manufacturing is measured using the buy-to-fly ratio (BTF), which is the ratio between the raw material (buy) used to manufacture a part and the weight of the finished part (fly).
Taking aerospace as an example, machining or casting from raw billet has an average BTF ratio of 11:1 and can be as high as 30:1, meaning up to 95% of material is wasted. With metal 3D printing, the reverse of this is true: instead of wasting 95% of the material, 95% of the material is used in the final manufactured product.
Wasted material in traditional casting
vs
Wasted material in 3D printing
Making Things That Were Never Possible Before
Metal 3D printing offers unprecedented design freedom. When we find opportunities that allow us to rethink how we design, we can make things that previously were simply not possible.
This kind of shift can be seen by looking back at the construction of the Iron Bridge in 1779—the world’s first major bridge made from cast iron. Initially, engineers applied traditional designs to this new material, but soon they began to innovate, creating bridges that fully utilised cast iron’s properties.
Similarly, while metal 3D printing is currently being used to improve existing designs, the real potential lies in rethinking products from the ground up. Rather than simply tweaking existing products, we can ask: what if this product was designed from scratch with the freedom metal 3D printing allows?
This approach mirrors the Iron Bridge’s legacy—moving from old designs to new paradigms, demonstrating how new technologies can make what was once unimaginable a reality. The Iron bridge is 30.6 metres long and was a feat of engineering. Today, the Danyang-Kunshan Grand Bridge in China is 164km. It is only through this philosophy of reimagination that this seismic difference could be achieved.
Applying this approach, metal 3D printing enables the creation of intricate curvilinear internal passages, channels, and fluid flow paths that are challenging or impossible to achieve using traditional manufacturing techniques. This enhances the performance and efficiency of hydraulic components, by optimising fluid dynamics and reducing pressure losses.
Similarly, while metal 3D printing is currently being used to improve existing designs, the real potential lies in rethinking products from the ground up. Rather than simply tweaking existing products, we can ask: what if this product was designed from scratch with the freedom metal 3D printing allows?
More flow in a Domin S6 Pro than its cast version counterparts.
Customisation
Metal 3D printing makes it substantially easier to tailor components to specific applications or system requirements. The flexibility of the design and manufacturing process enables the rapid incorporation of design modifications, such as varying valve sizes, shapes, and flow characteristics for bespoke purposes.
The benefits presented by metal 3D printing give us an opportunity to rethink the design of hydraulic components with improved fluid dynamics and reduced energy losses. For instance, metal 3D printing manifolds and spools can be designed to optimise fluid flow, minimising resistive losses and improving overall system efficiency.
The New Stable Technology
In this white paper, we have explored the opportunities for positive change and highlighted some of the tools that can drive these improvements. Now, we return to the initial question posed and consider the solution:
If we were to design a product from scratch using today’s technology, how would we approach it?
By returning to a first-principles approach and redesigning hydraulic technology with innovations such as hall effect sensors, metal 3D printing, modern electronics, and advanced design and simulation techniques, we can establish a new stable technology.
This new technology will set the benchmark for years to come.
We can address the energy efficiency problem while still achieving the performance and precision required by hydraulic systems to power our world.
Domin’s utilisation of these opportunities to develop high-performance hydraulic technology—high-speed control valves and ultra-compact pumps—enables a complete redesign of hydraulic systems, pushing the boundaries of efficiency and performance.
By taking a first-principles approach and combining the modern tools available to us, we have developed a high-speed control valve that controls the motion of hydraulic fluid in new ways.
Modern Electronics
Traditionally, servo valves will have a large electronics housing on the side of the valve. Our solution is a slim, modular PCB approach that sits within the housing of the valve.
Magnetic Hall Effect Sensors
Most direct drive valves currently use large, bulky linear position transducers with relatively average resolution and performance. We can harness the benefits of the minuscule magnetic hall effect sensors, whilst achieving greater control accuracy.
Brushless DC Motors
Advanced Control Algorithms and Firmware
Metal 3D Printing
Domin Valves
Traditionally, designing a radial piston pump involved navigating a complex set of compromises, particularly in managing high radial forces to ensure efficiency and reliability.
The optimal solution is a pump with a pressure-balanced pintle along its length. However, achieving this requires a highly intricate hydraulic commutation system that ports the inlet and outlet around the pintle and along its length. Despite significant efforts in developing radial piston pumps over the last century, the manufacturing techniques of the time were insufficient to realise this design.
Today, using the advantages provided by metal 3D printing and a first-principles redesign, we have developed a patent-protected radial piston pump for use in hydraulic systems that is lightweight, with high power density and high torque.
When integrated into more complex assemblies, such as power packs and valves, it brings substantial improvements in size, energy efficiency and power to its applications. This allows us to efficiently generate hydraulic energy with a compact size and low weight, making it more energy efficient without compromising on performance.
Traditionally, designing a radial piston pump involved navigating a complex set of compromises, particularly in managing high radial forces to ensure efficiency and reliability.
By leveraging metal 3D printing and advanced electronics, we have developed hydraulic technology that is not only more efficient, but also higher performance and extraordinarily compact. These improvements lead to reduced material usage and lower energy consumption during both manufacturing and operation, contributing to a more sustainable future.
By recognising the enormous inefficiencies in today’s energy use and rethinking the problem from a fresh perspective, we have developed solutions that significantly impact energy utilisation within hydraulics.
These solutions allow us to combine our valve and pump technologies in various configurations, unlocking substantial benefits across the automotive, aerospace, and industrial sectors
By reimagining traditional hydraulic technologies through the lens of modern advancements—such as metal 3D printing, advanced motors and sensors, and cutting-edge electronics—we can overcome the significant inefficiencies that have long plagued these systems, and define the new stable technologies that will build our world.
However, the challenges posed by outdated hydraulic technology also present an immense opportunity. By applying a first-principles approach—asking how we would design these systems if we were creating them today with all the technological tools at our disposal—we open the door to a new era of hydraulic innovation.
The integration of metal 3D printing, for example, allows for the creation of components that are not only lighter and more efficient, but also tailored to optimise fluid dynamics in ways previously thought impossible. Similarly, the adoption of brushless DC motors and hall effect sensors provides unprecedented precision and durability, further enhancing system performance whilst reducing energy consumption.
Looking Forward
As we look to the future, the implications of this revolution in motion control are profound. The potential to reduce energy consumption by up to 90%, extend the range of electric vehicles, and even significantly enhance the efficiency of combustion engines, highlights the critical role that advanced hydraulic systems will play in the sustainable industries of both today and tomorrow. In a world where the demand for efficiency continues to rise, the innovations explored in this paper are not merely desirable—they are essential.
By embracing these advancements, we are not only addressing the inefficiencies of the past, but also laying the groundwork for a future where motion control systems are more efficient, more reliable, and more sustainable. The journey towards a more prosperous and environmentally responsible world begins with the decisions we make today, and the technologies discussed here offer a clear path forward. This revolution in hydraulics is not just about improving systems; it’s about redefining the very principles on which we build our world.
Calling For a Revolution in Hydraulic Systems
At Domin, we have reimagined traditional, outdated hydraulic technologies by looking at the problem of inefficiency through a new lens. We are not only calling for this revolution in hydraulics, we are driving it. Keep an offline version of this white paper by downloading it here.
