​

Lightweight, corrosion-resistant submersible pump developed using CFD optimization, parametric CAD, and additive manufacturing for faster prototyping and improved hydraulic performance.

Project Description

KS Projects developed a fully functional submersible pump designed to reduce development time while maintaining the strength, reliability, and hydraulic performance required for demanding water-handling applications.

The pump was engineered using a combination of parametric 3D CAD, computational fluid dynamics (CFD), material engineering, and additive manufacturing. A parametric design approach allowed our engineers to quickly modify impeller geometry, internal flow paths, sealing features, and housing components throughout the development process.

​

CFD simulations were used to analyze fluid flow, pressure distribution, cavitation margins, and impeller performance. The results guided multiple design iterations and helped optimize the impeller profile, ultimately improving overall pump efficiency.

To reduce weight and manufacturing lead times, the housing was developed using high-temperature, glass-filled engineering polymers. These materials provided the mechanical strength and corrosion resistance required for the application while offering a lightweight alternative to conventionally machined metal components.

By combining CFD analysis with rapid 3D-printed prototypes and physical flow testing, KS Projects significantly shortened the design-test-improve cycle and created a scalable pump platform that can be adapted for different flow rates and operating requirements.

Engineering Capabilities

• Parametric 3D CAD Design – Pump body, impeller, stator vanes, sealing features, and O-ring pockets

• CFD Analysis & Impeller Optimization – Flow behavior, head/flow performance, pressure distribution, and cavitation analysis

• Material Engineering – Glass-filled PA and ASA polymers, stainless steel inserts, and engineered sealing solutions

• Additive Manufacturing – FDM and SLS housings with SLA-produced precision impeller prototypes

• Flow Testing & Validation – CFD-to-prototype testing and performance evaluation

• Design for Maintenance – Quick-twist housing and drop-in cartridge seal for easier servicing

Project Results

✅ 70% faster prototype development cycle compared with conventional machining

✅ 40% reduction in pump weight while maintaining structural rigidity under full operating head

✅ 12% improvement in pump efficiency following CFD-driven impeller optimization

✅ Reduced development time through rapid CAD, CFD, 3D printing, and testing iterations

✅ Created a scalable pump design platform that can be modified for different flow rates and operating conditions

Technologies & Expertise

Submersible Pump Design | Mechanical Engineering | CFD Analysis | Impeller Optimization | 3D CAD | Additive Manufacturing | 3D Printing | Rapid Prototyping | Fluid Dynamics | Material Engineering | Pump Engineering