This study aims to research and develop Pipe Flow Generators. The focus in this paper is on the rotor design for pipes of different sizes. Modern engineering tools such as Computational Fluid Dynamics (CFD) software and Rapid Prototyping technology are utilized to facilitate the numerical and experimental studies. The CFD numerical simulations consist of two and three-dimensional transient and steady analyses. These simulations were conducted to find the relationship between the flow rate, blade geometry and number of blades. During the experimentation process, Rapid Prototyping Technology (RP) was used to fabricate many different types of turbine geometries to test different impeller parameters. RPM and voltages where measured for each turbine design. The study leads to several important findings for better pipe flow generators design.