Wexmar provides custom manifold machining for fluid power, process and instrumentation OEMs. We machine hydraulic and pneumatic manifold blocks to your drawing or 3D model at our shop in Canastota, New York, using Mazak horizontal machining centers built for multi-face, deep-hole work. Every quote is reviewed by a human estimator who reads the porting before pricing it.
What manifolds do and who buys them
A manifold is a block that routes fluid between valves, pumps, cylinders, sensors and fittings through internal drilled passages. It replaces loose tubing and fittings with one compact, leak-resistant body. Buyers include hydraulic power unit builders, mobile equipment and industrial machinery OEMs, fluid power distributors, lubrication and coolant system suppliers, gas and instrumentation panel builders, and defense ground equipment programs. Designs range from simple distribution blocks to dense valve manifolds with cartridge cavities on four or five faces.
CNC machined manifolds on horizontal machining centers
Manifolds are a natural fit for horizontal machining. We run six Mazak horizontals: two FH4800s, a PFH4800, a Nexus 4000-II and two Nexus 5000-II machines, all with pallet changers and 4th-axis rotary tables. A block fixtured on a tombstone can be indexed to each side face and machined in one setup, which keeps intersecting passages on true position relative to each other. Horizontal spindles also clear chips out of deep holes by gravity, which matters when drilling long cross passages.
These are 3- and 4-axis machines. Compound-angle ports that a 5-axis machine would reach in one clamping are handled with angle fixtures and additional setups, and we will review those features with you at quote stage. Round manifold bodies and cartridge sleeves are turned on our Mazak and Doosan lathes. See horizontal CNC milling and our machine list.
Manifold materials
- Aluminum: 6061-T6 and 2024 for pressures within the alloy's rating; light and fast to machine.
- Steel: 1018, 12L14 and ductile iron bar for higher pressure hydraulic manifolds.
- Stainless: 303, 304 and 316 for corrosive fluids, food and process service.
- Others: brass, Monel and engineered plastics such as acetal and PVDF for chemical or low-pressure service.
Critical manifold features and how we hold them
- Port geometry: SAE J1926 straight thread O-ring ports, ISO 6149, NPT, BSPP and ISO 228 ports cut with dedicated form tools so the spot face, O-ring seat and thread are concentric.
- Cartridge valve cavities: machined with cavity form tools to the valve maker's specification, then gaged.
- Passage intersection: deep holes are drilled with controlled drift so cross passages meet as designed, with break-throughs deburred.
- Mounting patterns: ISO 4401 (D03, D05 and similar) valve interfaces held for position and surface flatness.
- Cleanliness: internal burrs and chips are removed and passages are blown out before inspection.
Typical tolerances and finishes
| Feature | Typical tolerance | Tighter on request |
|---|---|---|
| Port position | ±0.005 in | 0.002 in true position |
| Cartridge cavity bores | Per valve spec | Per valve spec |
| Valve mounting face flatness | 0.001 in | 0.0005 in |
| Block overall dimensions | ±0.005 in | ±0.002 in |
| Threads | UN 2B / NPT | UN 3B |
| Sealing face finish | 63 Ra | 32 Ra |
Secondary operations
Anodizing for aluminum manifolds, zinc or nickel plating and black oxide for steel, and passivation for stainless are performed through qualified outside processors. Pressure testing requirements should be noted on the drawing so we can plan for them with you. Plugging, assembly of ball plugs, and installation of fittings or cartridges can be quoted on request.
Quantity patterns
Manifold work often starts with 1 to 5 prototype blocks for system testing, then moves into production lots of 25 to 250 per release. Pallet changers let us run production blocks unattended on our second shift.
Inspection
Port location and cavity depths are verified on our Brown & Sharpe CMMs, and threads with go/no-go plug gages. Passages are checked for break-through and cleanliness visually and with pin gages. CMM reports, AS9102-format first article inspections and material certs are available. See inspection and quality.
Getting a quote
Send a STEP model plus a drawing that calls out port types, cavity specs and pressure rating. You can upload a drawing for an instant estimate, and an estimator will confirm pricing. Or call (315) 400-2654. Related: valve bodies.