NKU mechanical engineering student Collin Couch helps SD1 save big through 3D printing initiative

Sanitation District No. 1 (SD1) has begun printing its own equipment components to significantly reduce the cost of maintaining its facilities.

Collin Couch, SD1’s facilities maintenance technician — a mechanical engineering student at Northern Kentucky University — is an integral part of the project, which is expected to save taxpayers thousands of dollars this year, with more expected as the 3D printing program develops.

Collin Couch shows one of the passive guide components made with a 3D printer. (Photo by SD1)

One of the first applications of the new initiative at SD1 is sewer inspection camera components. Sewer inspection cameras play a critical role in maintaining northern Kentucky’s sewage and stormwater systems. The specialized cameras work in tandem with tracked robots to collect visual data on what’s going on in the sewers, allowing SD1 to identify problems and prioritize improvement projects across the region.

SD1 spends thousands of dollars annually maintaining these sewer inspection cameras. Increasing costs associated with repairing these devices were a constant challenge for SD1.

To reduce camera repair costs, SD1 introduced an in-house maintenance and repair program a few years ago, which continually seeks savings within the equipment maintenance department. Last fall, employees began investigating whether SD1 could 3D print spare parts for cameras instead of ordering expensive parts from vendors.

Couch has extensive experience in 3D printing, dating back to his days as a student at Conner High School. His experience ranges from printing general purpose items to printing critical replacement parts for home repairs.

CAD scheme for the passive guide (image from SD1)

He first drew the component in CAD (a 3D modeling program) and produced a 3D printed passive guide prototype at home. He and other SD1 officials tested the prototype in the field, experimented with different materials and received valuable feedback from SD1 camera crews.

After a few months, the team produced a 3D printed passive guide that performs just as effectively as the original part sourced from vendors—at a fraction of the cost. The small plastic guide cost SD1 about $650 a piece, but can now be 3D printed in-house for about 30 cents.

Switching to in-house printing of these components will save SD1 nearly $40,000 annually, and Couch looks forward to finding other ways SD1 can make savings using 3D printing technology.

“I’ve always loved making things,” Couch said. “Being creative on this job and finding new ways to save money and improve SD1’s cameras has been a great experience.”

From Sanitary District #1