Charles R. Goulding and Preeti Sulibhavi discover how Pentair is quietly transforming the water solutions industry by integrating 3D printing into its R&D and production process—cutting lead times, customizing components, and building a smarter, more sustainable future.
Pentair, a global leader in water solutions, recorded US$4.1 billion in sales in 2024 and employs nearly 10,000 people across its operations. The company’s focus is clear: deliver smart, sustainable water solutions that support residential, commercial, industrial, and infrastructure needs. As the demand for clean water intensifies and systems become more complex, Pentair stands out by combining traditional engineering with modern digital manufacturing—including 3D printing.
This article examines Pentair’s core products and explores how 3D printing is reshaping the way components are designed, prototyped, and produced in the water solutions industry.
What Does Pentair Do?
Pentair operates in three main segments: Flow Technologies, Water Treatment, and Pool. Each is essential in delivering comprehensive water management solutions to a diverse customer base.
1. Flow Technologies
This segment includes pumps, valves, and control systems that move water efficiently. Applications include agriculture, irrigation, wastewater, and industrial processes. For example:
- Submersible pumps for deep well applications.
- Vertical turbine pumps for municipalities.
- Smart pump control panels that integrate with monitoring systems.
2. Water Treatment
Pentair offers advanced filtration and purification systems to provide clean and safe water. Products in this category include:
- Whole-house water filtration systems that remove contaminants like chlorine, sediment, and lead.
- Commercial reverse osmosis systems used in restaurants, hospitals, and breweries.
- Point-of-use filters for homes and businesses.
3. Pool
Pentair is a top name in pool equipment. Their product range includes:
- Variable-speed pool pumps with energy-efficient motors.
- Pool filtration systems using cartridge, sand, or DE filters.
- Automation systems for remote pool monitoring and control.
Each of these areas depends on parts that must endure corrosion, pressure, temperature changes, and precise fluid dynamics—making them perfect candidates for innovation through 3D printing.
How 3D Printing Fits In
3D printing is a tool that can drastically reduce costs, timelines, and limitations in the design and production cycle. For Pentair, integrating 3D printing into its R&D and production process delivers benefits in three main areas:
1. Rapid Prototyping
Water systems require rigorous testing, particularly for pressure tolerances, chemical compatibility, and flow rates. With 3D printing, engineers at Pentair can produce functional prototypes in a matter of hours rather than weeks.
Example:
A new nozzle design for a high-efficiency sprinkler head can be printed and field-tested the same day. Engineers can tweak parameters like angle, aperture, or water flow distribution, print again, and test iterations rapidly.
2. Customization and Complex Geometry
Water systems often need customized fittings, especially in retrofitting jobs or tight mechanical environments. Traditional methods of machining or injection molding struggle with intricate designs or short production runs.
Example:
A custom manifold that connects multiple filtration inputs can be 3D printed in a single part with internal baffles and channels—something nearly impossible with conventional manufacturing.
3. Lightweight, Durable Parts
Using engineering-grade materials like nylon, polycarbonate, or even metal-infused filaments, Pentair can print components that are not only lighter but also optimized for performance.
Example:
Replacement impellers, made from high-strength 3D printed composite materials, reduce weight and improve pump efficiency, while cutting lead times from weeks to days.
In-House Use vs. End-User Products
At this stage, most of Pentair’s 3D printing applications happen in-house. The primary focus is prototyping, mold creation, and small-batch production. However, the shift toward direct 3D printed components in field-ready systems is already beginning.
3D printed parts are being integrated into test systems and short-run commercial projects, especially in industrial and R&D settings where unique configurations are needed. As certifications for 3D printed components (like NSF/ANSI for potable water) become more standardized, we can expect more widespread deployment.
3D Printing Examples in Pentair’s Context
Let’s zoom in on a few practical, hypothetical examples where 3D printing is changing the game.
Example 1: Water Filtration Cartridge Housing
Traditional cartridge housings are made via injection molding. But what if a customer needs a compact unit with a non-standard inlet configuration? With 3D printing:
- A housing is designed to fit in a tight cabinet.
- Custom inlet/outlet diameters match existing plumbing.
- Internal structures optimize water turbulence for better filtration.
This saves on tooling costs and delivers a bespoke product in days.
Example 2: Flow Test Rigs
Pentair often builds custom rigs for simulating different flow scenarios. 3D printing lets the company fabricate adapters, sensor holders, and pipe junctions unique to each experiment.
- No need to machine or wait for overseas components.
- Quick modifications if test results are off-target.
- Full compatibility with existing lab equipment.
Example 3: Jet Nozzles for High-Pressure Systems
High-pressure spray systems require precision-engineered nozzles. 3D printing allows Pentair engineers to:
- Experiment with internal swirl patterns.
- Minimize backpressure while maximizing spray radius.
- Print the nozzle in corrosion-resistant resin or metal.
These prototypes help optimize performance before mass production.
Sustainability and Efficiency Gains
3D printing isn’t just about speed and flexibility—it also supports sustainability goals. Here’s how:
- Less waste: Traditional subtractive manufacturing (cutting, milling) wastes material. 3D printing uses only what’s needed.
- Localized production: Printing parts in-house reduces transportation emissions.
- On-demand manufacturing: Spare parts can be printed as needed, reducing the need for storage and large inventories.
As a water company focused on sustainable resource water management, these benefits align perfectly with Pentair’s broader mission.
The Future: Digital Inventory and Distributed Manufacturing
Pentair is laying the groundwork for a future where digital part libraries replace physical stockrooms. With secure 3D print files and certified materials, parts could be produced at local hubs or even on customer premises.
This model would:
- Reduce lead times for replacement parts.
- Enable ultra-customized solutions at scale.
- Support service operations globally without costly logistics.
Below is a table that presents Pentair’s R&D expense over the past few years. This data supports the argument we are making in terms of Pentair’s commitment to innovation.
The Research & Development Tax Credit
The now permanent Research and Development (R&D) Tax Credit is available for companies developing new or improved products, processes and/or software.
3D printing can help boost a company’s R&D Tax Credits. Wages for technical employees creating, testing and revising 3D printed prototypes are typically eligible expenses toward the R&D Tax Credit. Similarly, when used as a method of improving a process, time spent integrating 3D printing hardware and software can also be an eligible R&D expense. Lastly, when used for modeling and preproduction, the costs of filaments consumed during the development process may also be recovered.
Whether it is used for creating and testing prototypes or for final production, 3D printing is a great indicator that R&D Credit-eligible activities are taking place. Companies implementing this technology at any point should consider taking advantage of R&D Tax Credits.
Conclusion
Pentair’s embrace of 3D printing isn’t just a matter of adopting new technology—it’s a practical, strategic move that enhances speed, efficiency, and customer responsiveness. From prototyping water filtration housings to building custom flow systems, additive manufacturing is becoming a quiet force behind the company’s innovation engine.
While many of these developments are still behind the scenes, the writing is on the wall: as 3D printing materials and certification standards mature, the water solutions industry will transform. And companies like Pentair are already plumbing the depths of what’s possible.
