Revolutionizing Naval Engineering: The Future of 3D Printing in Shipbuilding
The shipping industry has undergone a significant transformation in recent years, with the adoption of innovative technologies such as additive manufacturing. 3D printing has enabled the production of ship and naval components with unprecedented efficiency and sustainability. By reducing material waste, optimizing manufacturing time, and allowing for highly personalized conceptions, 3D printing has emerged as a revolutionary solution for the maritime industry.
In this context, Caracol, an Italian company specializing in large-scale additive manufacturing solutions, has collaborated with the V2 group to develop the world’s first 3D-printed monohull catamaran, measuring 6 meters in length and designed for high-sea navigation. This innovative project showcases the potential of large-format additive manufacturing (LFAM) technology in the naval construction industry.
LFAM technology, utilizing the HERON AM ROBOT PLANFFORM, allows for the production of massive parts in a single printing process. This breakthrough represents a significant step forward in the navigation industry, as it enables the industrialization and scalability of large-format manufacturing processes, optimizing each stage of the post-processing design.
The 3D printed monohull catamaran, printed using the Caracol LFAM technology, is a testament to the innovative potential of this technology. The catamaran’s design and segmentation process requires specific adjustments due to its size and geometry, but each model can be produced once and replicated in future production.
The company uses RPP GF (recycled polypropylene material containing 30% fiberglass), optimizing printing time and ensuring the mechanical resistance of 3D printed catamarans. Additional finishing techniques, such as CNC machining, frost coating, and paint coating, as well as in-depth testing of the final hull, are also necessary. The latter is crucial for the future industrialization of 3D printed ships.
The manufacturing process of the catamaran took approximately 160 hours, reducing the delivery time by 20%. This achievement underscores the potential of 3D printing in streamlining the production process and improving efficiency.
The use of a high-flow (HF) extruder and 8 mm nozzle allows for optimal material deposition and high print quality, resulting in a 30% reduction in waste and a final weight of 1,200 kg. This demonstrates the potential of LFAM technology in producing complex and high-performance marine structures.
The project showcases the potential of large-format additive manufacturing in the production of complex and high-performance marine structures. Caracol and the V2 Group continue to improve this manufacturing method, aiming to expand its applications in the maritime sector. The industrialization of this process will enable more evolved, sustainable, and accessible production, solidifying technology as a viable solution for the manufacture of marine components.
