The Challenge

A client needed a replacement for a specialized fountain nozzle that had become damaged or lost. The component was complex, requiring a two-piece assembly to fasten securely around a "vessel" wall, with threads entering from the bottom to lock the unit in place. Off-the-shelf plumbing fixtures rarely account for specific vessel thicknesses or proprietary spray patterns, making a custom-engineered solution necessary.

The Solution

The nozzle was reverse-engineered in Fusion 360 by modeling the internal and external threads based on the NPT (National Pipe Taper) standard. To ensure a leak-proof seal without over-stressing the plastic, the thread profiles were adjusted for a "light interference fit," providing a tighter, more secure connection than standard hardware.

PETG was selected as the build material for its excellent hydrophobic properties and long-term durability in submerged environments. The top apertures were meticulously modeled to match the flow dynamics of the original part, ensuring the fountain’s aesthetic spray pattern remained consistent with the rest of the installation.

Key Features

Material: PETG (Chemical and water-resistant)
Design Software: Fusion 360
Engineering: Precision NPT threads with custom interference fit adjustments
Assembly: Two-piece "sandwich" design for through-vessel mounting
Functional Matching: Top apertures modeled to replicate original spray dynamics
Application: Replacement mechanical hardware for water features

The Result

The 3D-printed replacement provided a perfect mechanical fit that was unavailable through traditional retail channels. By adjusting the thread tolerances specifically for 3D printing, the new nozzle achieved a superior seal compared to the original part, extending the service life of the fountain with a durable, water-resistant component.

Custom NPT-Threaded Fountain Nozzle