Prototypes are important for product development
For most of the development phase of a product, the project team works with prototypes. In order to remain competitive, it is essential for models and sample parts to be available rapidly. Prototypes are necessary both for product design and for subsequent series production.

There is a wide range of processes that make it possible to manufacture complex models and sample parts quickly. At Geberit, this is done directly based on CAD data. We call this process “rapid prototyping”. It opens up new potential for cutting development times and costs.

CAD data generated by the designers serves as the basis for manufacturing rapid prototyping parts. They are the main elements of modern product development. The Prototype Building department used to buy in these technology services from external providers. Now, the department has bought its own 3D printer so that prototypes can be manufactured even faster and for a lower outlay.

Process description
The CAD data control the 3D printer. Instead of ink, the 1536 nozzles on the printer head spray a liquid photopolymer that is cured by two UV bulbs. At the same time, an easily detachable support structure is built up according to the geometry of the component. The layer thickness is 0.016 mm. In this way, a new prototype is created layer-by-layer and can subsequently be removed from the support structure for immediate use.

Areas of application
The components are very well suited for:

• Design and geometry checking
• Manufacturing functional models
• Prototypes that are then directly installed or tested with water

	W	A full platform, built in 13 hours overnight, can then be removed from the 3D printer like taking a baking mould out of the oven. Next, the support material enclosing the parts which still has a gelatinous texture has to be rinsed off with a water jet and the prototype parts are ready.
		Examples: Water section housing tested in the laboratory with up to 12 bar water pressure.
		Bathtub overflow head that was used as a demonstration model for checking installation and measuring the overflow capacity.

CFD – die intelligent software behind it all
What so far could mainly be found at enterprises of the aerospace or automotive industries has now also been introduced at Geberit: with the aid of state-of the-art software, the simulation of flows may be integrated into the product development state at a very early stage. With the aid of computer, a preliminary selection is made and only the most promising versions are taken to the prototype workshop and subsequently tested at the laboratory.

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Colors show improvement potential Why something functions better or worse cannot be learnt at the laboratory but it is shown in the computer simulation. Low velocities in the flow are displayed in green to blue, high velocities in red to orange.