Round Table
Material sustainability, ESG criteria, and LCA in the boating industry: new perspectives for the supply chain


Additive manufacturing enters the nautical sector under full sail

3D printing technology has already revolutionized many industrial sectors and now the marine industry is beginning to adopt additive manufacturing at an increasing rate. Shipyards are turning to additive manufacturing to improve production efficiency, reduce costs, and enhance the performance and sustainability of everything related to the maritime sector: boats, vessels, surfboards, ships.

Companies are developing 3D printed components that meet hydrodynamic and durability requirements while reducing waste, benefitting from greater design flexibility avoiding supply chain bottlenecks. Innovative technologies like 3D printing can reduce production and operating costs, ensuring a strong supply chain of spare parts, even for ships and offshore platforms. This technology can produce complex shapes thus facilitating repairs and maintenance.

However, its use must be facilitated by adequate knowledge, development of procedures for the production of 3D printed component and (possibly) the standardization of 3D printers.


The technology behind 3D printing (AM) in the marine industry

Additive Manufacturing (AM), is used to create a wide variety of components for the marine industry, including hull components, propellers, rudders, spare parts, and many more. The materials used range from polymers and composites to advanced metals such as titanium, steel, and aluminum alloys, each selected considering the specific performance and environmental factors.

The materials used in the production of marine components must be lightweight, able to withstand strong impacts without damage, not water absorbing, naturally resistant to marine growth, distribute weight evenly, and possess a good degree of resistance to corrosion and UV rays.

Various 3D printing techniques are used; FDM is the dominant method, while WAAM is increasingly used for large components such as propellers. Polymers are the most common materials for components, but composites are also becoming increasingly popular, being used for structural parts. Carbon fiber-reinforced thermoplastics offer an excellent strength-to-weight ratio, perfect for hulls and high-performance components. Fiberglass is ideal for structures requiring good flexural strength and cost-effectiveness.

A major challenge for further adoption is ensuring components are safe enough to withstand adverse weather conditions: 3D-printed components must meet stringent performance and safety requirements.

Advantages of 3D Printing for Boat Manufacturing

One of the most significant advantage of 3D printing part of a boat, is the freedom it offers from design constraints. Traditional boatbuilding methods often rely on complex and expensive molds and tools, which require high initial costs. Thanks to AM, complex and customized boat designs can be created without incurring upfront costs, allowing naval architects to explore new possibilities and push the boundaries of aesthetics and functionality. AM is also revolutionary for functional prototyping. Hull models, propeller blades, and internal structures can be tested, ensuring good positive and hydrodynamic efficiency before being brought to final production. This optimizes the design while minimizing potential errors. Last but not least, lead times are reduced and on-demand production is possible.

Focusing on the implementation of large-format 3D printing and emphasizing the use of sustainable materials is paving the way for this technological shift.

Furthermore, the 3D printing process minimizes waste production, allows for the use of environmentally friendly recycled materials, and reduces overall energy consumption, in line with global environmental goals. 3D printing of boats therefore stands as an ideal production method in an era where sustainability is the top priority.

Shipyards, technology companies, material suppliers, printing services, and research institutions work side by side, fostering an environment where ideas are exchanged, tested, and refined. This collaborative spirit drives the industry forward, ensuring that the latest advances are rapidly integrated into the 3D printing of boats.