污水基础设施密封新纪元:Xometry择幂科技帮助研发压力管道通用接头

Industry
Machine Building
Country
flag

Germany

Use case
Prototyping
Technology
3D打印
Product

污水压力管道通用接头

case hover image

我们的开发流程始于对潜在形状与密封方法的广泛头脑风暴。3D 打印在此阶段发挥关键作用,使我们能在确定最终生产材料前快速测试不同设计方案。由于最终材料在早期原型阶段成本过高且耗时,我们专注于内部制作小比例测试模型,再通过 Xometry 择幂科技生产大尺寸原型以确保便捷与精度。

Johannes König 工程师 BK Pipecheck

嗨,我是 Johannes König,BK Pipecheck 的一名工程师。我的工作侧重点是保障污水压力管道的可靠性,这一基础设施中至关重要却常被忽视的环节。我的工程学背景与问题解决能力将我引入这一领域,并致力于研发实用解决方案以预防代价高昂的维修与系统故障。

对污水管网进行现场压力测试

在先前的研究项目中,我与德国奥格斯堡工业大学的团队共同开发了一套具有法律约束力的污水压力管道测试规程。在对多家运营商的污水管网进行现场压力测试时,我们发现一个重大问题:近 50% 压力管道的端部处于无法密封的状态。鉴于压力管道约占整个污水系统的 10%,这一问题影响重大——若管道无法有效密封,可能需整体更换检修井结构,这一过程成本高昂且耗时漫长。

这一发现促使我研发一种能够快速、以低成本密封压力管道的通用接头,避免不必要的基础设施更换。

通用接头原型设计

通用接头原型设计

开发通用解决方案

为实现易用性,该通用接头需作为多功能通用解决方案,无缝适配不同尺寸与材质的管道——这也是研发过程中最大的挑战。此外,污水环境极其严苛——持续的污水流动、化学腐蚀与高机械载荷意味着任何解决方案必须兼具耐久性且易于安装。由于污水总是在持续流动,安装过程需快速可靠,同时干扰最小。

我们的开发流程始于对潜在形状与密封方法的广泛头脑风暴。3D 打印在此阶段发挥关键作用,使我们能在确定最终生产材料前快速测试不同设计方案。由于最终材料在早期原型阶段成本过高且耗时,我们专注于内部制作小比例测试模型,再通过 Xometry 择幂科技生产大尺寸原型以确保便捷与精度。

改进设计并选择正确材料

我们与奥格斯堡工业大学合作,通过学生项目组启动了对通用接头最佳材料与粘合剂的研发。粘接是极具挑战性的环节,需确保从铸铁、纤维水泥到 PVC 与 PE(聚乙烯)等常见材料均具备粘接适配性。塑料材料尤其难以粘接,因其表面光滑特性导致界面结合力不足。连接的耐久性与粘合剂的均匀分布对长期性能至关重要。为模拟真实工况条件,我们采用 1:1 比例打印模型以复现实际安装场景。

拉力测试样本粘合

拉力测试样本粘合

粘接拉力测试

粘接拉力测试

粘接拉力测试

通过多次迭代优化,我们改进了接头的形状、密封方式与安装流程。最新设计原型配有精确定位垫片,并已通过透明管道测试验证粘接与密封效能。

各种 3D 打印原型

各种 3D 打印原型

带有粘接管代的各种 3D 打印原型

带有粘接管代的各种 3D 打印原型

原型被设计为便于向管道后方间隙注入粘接剂,从而实现可靠粘接

原型被设计为便于向管道后方间隙注入粘接剂,从而实现可靠粘接

原型被设计为便于向管道后方间隙注入粘接剂,从而实现可靠粘接
原型被设计为便于向管道后方间隙注入粘接剂,从而实现可靠粘接

扩大规模,适应未来

3D 打印在原型开发和测试中发挥了关键作用,而我们下一步将转向 CNC 加工与注塑成型以实现量产。这些方法将帮助我们实现所需的强度、耐久度与规模化生产能力,从而满足实际污水管网大规模应用的需求。我们已与多家管网运营商建立联系,其对此项技术开发表现出浓厚兴趣。此外,我们正与目前采用传统封堵工艺的污水压力管道施工企业展开合作洽谈。我们的开发方案必须在成本与安装效率上匹配或超越现有解决方案。

展望未来,我们将持续测试并优化设计,以实现通用接头市场化应用的目标。此项创新有望显著降低污水运营商的成本——并通过水费中包含的管网维护费用间接惠及公众,同时减少不必要的基础设施更换。

经验总结与对创新者的建议

本项目最重要的经验之一是认识到迭代与灵活性的重要之处。没有哪种解决方案从一开始就是完美无缺的——每个原型、失败与调整都让我们更接近理想产品。我对应对类似工程挑战的创新者有以下建议:拥抱快速原型开发、善用专家协作,并对可能改良设计的意外发现保持开放态度。

在 BK Pipecheck,我们致力于让污水处理基础设施更高效、可靠且更具成本效益,并期待见证这一通用接头对行业的实质性影响。

Explore More Case Studies

复刻 Barentsz 钟:传统与现代制造技术的融合 card image

复刻 Barentsz 钟:传统与现代制造技术的融合

Machine Building Consumer Goods
3D打印 CNC Machining Sheet Metal
Prototyping, R&D
Read Story

钟表协会始终遵循着尊重传统工艺与拥抱现代创新之间的平衡。其中一项创新是采用 3D 打印技术,该技术已成为塑料钟表零件原型制作的宝贵工具。通过 Xometry  择幂科技获取高质量的 3D 打印部件,我们可在开始金属量产前对设计进行高效验证。该方法让我们能以最低材料浪费与成本,优化复杂机械结构(如齿轮组)。

Peter Chevalier 协会成员 荷兰钟表协会
Read Story
为高级工作场所安全设备获取部件:Genesi & Xometry 择幂科技 card image

为高级工作场所安全设备获取部件:Genesi & Xometry 择幂科技

Machine Building
3D打印 CNC Machining
High-Volume Manufacturing
Read Story

我们通过在线搜索发现了 Xometry 择幂科技,之后便迅速成为了制造 3D 打印与 CNC 加工部件的理想合作伙伴

Enzo Cortinovis 研发部人员 Genesi
Read Story
了解Xometry 择幂科技如何通过CNC加工提升Pembleton汽车的制造质量与效率 card image

了解Xometry 择幂科技如何通过CNC加工提升Pembleton汽车的制造质量与效率

Automotive Machine Building
CNC Machining
Prototyping, R&D
Read Story

我们已经使用 Xometry 择幂科技多年了,而且我们发现与他们的合作非常简单。他们非常积极地帮助我们寻找工程和制造解决方案,并提供非常准确的交货时间。在极少数情况下出现延误时,他们会及时提前告知并提供可能的替代方案来满足我们的要求

Phil Gregory 创始人 彭布尔顿汽车公司(Pembleton)
Read Story
Designing a Hose Clip for the Beverage Industry: From Faculty Project to First Business Venture card image

Designing a Hose Clip for the Beverage Industry: From Faculty Project to First Business Venture

Machine Building
Sheet Metal
Prototyping
Read Story
Exploring Magnetic Couplings: No Gears, No Belts, Just Magnets card image

Exploring Magnetic Couplings: No Gears, No Belts, Just Magnets

Machine Building
3D Printing Sheet Metal
R&D
Read Story
How We Set Tunneling Records and Won the Not-a-Boring Competition card image

How We Set Tunneling Records and Won the Not-a-Boring Competition

Machine Building
CNC Machining
Prototyping
Read Story

The lessons we learned go far beyond mechanics. We reflect on three key takeaways: people are the ultimate success factor — both the team and its supporters; divide and conquer: breaking the project into subsystems prevents chaos and enables parallel innovation; and industry partners like Xometry are strategic enablers, not just suppliers.

Read Story
Füllen’s Desktop Plastic Injection Machine MiniMolder Manufactured with Xometry card image

Füllen’s Desktop Plastic Injection Machine MiniMolder Manufactured with Xometry

Machine Building
CNC Machining
High-Volume Manufacturing
Read Story

We make the design, upload it to the Xometry Instant Quoting Engine. We see the price and delivery time immediately. Previously, we had to contact four or five different places separately. Now, we receive ready-to-assemble parts from a single channel.

Enes Bayam Co Founder Füllen
Read Story
Hybrid engines for the marine industry produced faster with on-demand manufacturing card image

Hybrid engines for the marine industry produced faster with on-demand manufacturing

Machine Building
CNC Machining Sheet Metal
Procurement, R&D
Read Story

With Xometry, we don’t have to go through that,” referring to simplified and faster quoting and manufacturing.

Graeme Hawksley Founder Hybrid Marine Ltd
Read Story
Revolutionary tunnel-boring machine made with on-demand manufacturing wins the Not-A-Boring Competition card image

Revolutionary tunnel-boring machine made with on-demand manufacturing wins the Not-A-Boring Competition

Machine Building
CNC Machining Sheet Metal
Prototyping
Read Story

he project had a very ambitious timeline since we had to plan, produce, test and ship our complex machine all within one year. The short and scheduled delivery times from Xometry were a great help in achieving this. We were also really satisfied with the quality of the parts provided by Xometry.

Dmitry Burlakov student the TUM Boring team
Read Story
Delft Hyperloop and Xometry Collaborate to Revolutionise Sustainable Travel Through High-Precision Manufacturing card image

Delft Hyperloop and Xometry Collaborate to Revolutionise Sustainable Travel Through High-Precision Manufacturing

Machine Building E-Mobility
CNC Machining Sheet Metal
Procurement, Prototyping, R&D
Read Story

We obtained around 3200 sheet metal parts and they were perfectly within tolerance. As a student team supplied entirely by partnerships, we were especially satisfied with the cost-quality ratio provided by Xometry.

Teije Nolen Partnerships Manager Delft Hyperloop
Read Story
FIMRO harnesses the power of 3D printing with Xometry for miniature models at trade fairs card image

FIMRO harnesses the power of 3D printing with Xometry for miniature models at trade fairs

Machine Building
3D Printing Selective Laser Sintering
Procurement, Prototyping
Read Story

We are at a lot of trade fairs and the problem is that our systems are rather large. The scaled-down version we have printed with Xometry – with a scale of about 1:10 – is usually around 7 meters long. So it would be quite time-consuming and expensive to present the standard size at trade fairs.

Matthias Mrochen Owner FIMRO GmbH
Read Story
How a Pittsburgh machinist adapted to the changing manufacturing industry card image

How a Pittsburgh machinist adapted to the changing manufacturing industry

Machine Building
CNC Machining
Procurement, High-Volume Manufacturing
Read Story

Every day I come in I know I am going to have five or six jobs on Xometry that I can fit into any free space that I might have out on the floor. It is just really nice to be able to have it , because always in the back of my mind, I’m thinking, ‘Oh man, I have no new orders coming in from my current clients, but I could take this job that's right here [on Xometry] and keep busy for a while.’ That is huge for us.

Tim O’Donnell part owner Ashby Manufacturing
Read Story