A New Era of Sealing for Wastewater Infrastructure: Xometry Supports Development of Universal Fittings for Pressure Pipelines

Hi, I’m Johannes König, an engineer at BK Pipecheck. My work focuses on ensuring the reliability of pressurized wastewater pipelines, a vital yet often overlooked part of critical infrastructure. My engineering background and problem‑solving mindset led me to this field, where I develop practical solutions to prevent costly repairs and system failures.

During an earlier research project, my team from the Augsburg University of Applied Sciences developed a legally binding testing procedure for pressurized wastewater pipelines. While conducting on‑site pressure tests on wastewater networks operated by multiple service providers, we identified a major issue: nearly 50% of all pressure pipeline ends could not be properly sealed. Since pressure pipelines account for roughly 10% of the entire wastewater system, this problem carries significant implications. Poor sealing can require full replacement of inspection shaft structures — a highly expensive and time‑consuming process.

This discovery motivated me to develop a universal fitting capable of fast, low‑cost sealing for pressure pipelines, avoiding unnecessary infrastructure replacement.

Universal Fitting Prototype Design

Developing a Universal Solution

For ease of use, the universal fitting needed to function as a multi‑purpose solution that seamlessly adapts to pipelines of different sizes and materials — this represented our biggest development challenge. Additionally, wastewater environments are extremely harsh: constant wastewater flow, chemical corrosion and high mechanical loads demand solutions that are both durable and easy to install. Since wastewater flows continuously, installation must be quick, reliable and cause minimal disruption.

Our development process began with extensive brainstorming on potential geometries and sealing methods. 3D printing played a key role at this stage, allowing us to rapidly test different designs before finalizing production materials. As production‑grade materials are costly and time‑consuming for early‑stage prototyping, we focused on producing small‑scale test models in‑house, while relying on Xometry to manufacture large‑scale prototypes for convenience and precision.

Refining Designs and Selecting Optimal Materials

In collaboration with the Augsburg University of Applied Sciences, we launched student‑led research into the best materials and adhesives for the universal fitting. Bonding presented a major technical challenge, as compatibility was required for common pipeline materials ranging from cast iron and fiber cement to PVC and PE (polyethylene). Plastics were particularly difficult to bond due to their smooth surface, which results in low interfacial adhesion. Long‑term performance depended heavily on joint durability and even adhesive distribution. To replicate real‑world operating conditions, we printed 1:1 scale models to simulate actual installation scenarios.

Tensile test sample bonding & Adhesive tensile test

Through multiple iterations and optimizations, we improved the shape of the joints, the sealing method, and the installation process. The latest design prototype is equipped with precisely positioned gaskets and has been validated through transparent pipeline testing for bonding and sealing performance.

Various 3D printed prototypes with adhesive tubes

Prototypes were engineered to enable adhesive injection into gaps behind pipelines, ensuring robust bonding.

Scaling for the Future

While 3D printing was critical for prototype development and testing, our next step is to shift to CNC machining and injection molding for mass production. These manufacturing methods will deliver the required strength, durability and scalability for large‑scale deployment across real‑world wastewater networks. We have established contacts with multiple pipeline operators, who have shown strong interest in this technology. We are also in talks with wastewater pressure pipeline contractors that currently use conventional plugging solutions. Our design must match or outperform existing alternatives in both cost and installation efficiency.

Moving forward, we will continue testing and optimizing our design with the goal of commercializing the universal fitting. This innovation is expected to significantly reduce costs for wastewater operators — indirectly benefiting the public through lower network maintenance charges embedded in water tariffs — while minimizing unnecessary infrastructure replacement.

Key Takeaways and Advice for Innovators

One of the most important lessons from this project is the value of iteration and flexibility. No solution is perfect from the start — every prototype, setback and adjustment brings us closer to an ideal product. My advice for innovators tackling similar engineering challenges is to embrace rapid prototyping, leverage expert collaboration, and stay open to unexpected findings that can improve your design.

At BK Pipecheck, we are committed to making wastewater treatment infrastructure more efficient, reliable and cost‑effective, and we look forward to seeing the tangible industry impact of our universal fitting.