Scholarly record

AIRFLOW 3D: A LOW-COST DIY ORIFICE FLOWMETER FOR GAS FLOW MEASUREMENT

Dawid Pecak

Abstract

Accurate flow measurement is an essential aspect of industrial process monitoring, laboratory experimentation, and modern energy systems. Differential pressure flowmeters, particularly orifice-based devices, remain widely used due to their simplicity, robustness, and standardized measurement principles. However, conventional manufacturing of such components typically requires precision machining, which can increase production costs and reduce flexibility during prototyping and design optimization. This study presents the design, fabrication, and preliminary evaluation of a low-cost do-it-yourself (DIY) orifice flowmeter manufactured using additive manufacturing technologies. The project investigates the feasibility of replacing traditional fabrication methods with 3D printing to create a functional flow measurement component suitable for air or gas flow applications. The design process involved CAD modeling of the orifice geometry, selection of printing parameters and materials, fabrication of the prototype, and assessment of its operational performance based on differential pressure measurement principles. Special attention was given to the influence of manufacturing tolerances, surface roughness, and geometric accuracy on measurement reliability, as these factors are critical for pressure-based flow devices. The proposed solution demonstrates that additive manufacturing can significantly reduce production time and development cost while enabling rapid customization and iterative design improvements. The results indicate that 3D-printed orifice flowmeters may represent a practical solution for educational purposes, laboratory-scale testing, and selected low-cost industrial monitoring applications. This work highlights the integration of conventional fluid measurement techniques with modern digital manufacturing methods and suggests further potential for application in sustainable engineering and clean energy systems.

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