Home-D.E.E.P project completes WAAM 3D printed marine propeller blade section, advancing digitally enabled propulsion systems
A section of a next-generation marine propeller blade has been successfully 3D printed as part of the Digitally Enabled Efficient Propeller (D.E.E.P) project, a seven-month feasibility program exploring additive manufacturing for maritime propulsion. The component was produced using wire arc additive manufacturing (WAAM) in Nickel Aluminium Bronze (NAB), with the milestone marking progress toward lighter, more efficient, and digitally integrated ship propulsion systems.
The project is led byEnki Marine Ltd, a marine engineering company focused on propulsion system integration and commercialization, and brings together partners includingDEEP Manufacturing Ltd,Stone Marine Propulsion,TWI,Authentise,ASTM International, andNewcastle University. The consortium spans expertise in design, materials testing, digital workflows, certification, and hydrodynamic validation.
WAAM propeller development targets performance and manufacturing constraints
The D.E.E.P project is investigating how additive manufacturing can address limitations associated with traditional casting processes for marine propellers. Conventional methods can restrict design flexibility and limit performance gains , particularly in relation to geometry and material distribution.
The WAAM-based approach enables structurally and hydrodynamically optimized blade geometries. According to the project team, this can support reduced weight and improved hydrodynamic performance, while also allowing for the integration of digital monitoring capabilities.
The propeller blade design is being developed with the potential to incorporate real-time data collection, with the potential to enable vessels to monitor propulsion performance and adjust operational parameters such as engine power and speed. This approach could also support predictive maintenance strategies and autonomous optimization of propulsion systems.
Scaling WAAM for large-format maritime components
DEEP Manufacturing Ltd, a UK-based specialist in wire arc additive manufacturing and hybrid manufacturing for high-integrity structures, is responsible for manufacturing and production scaling within the project. The company is also expanding its international WAAM capabilities, including recent operations growth in Houston, Texas.
According to DEEP Manufacturing, WAAM offers potential lead time reductions of up to two thirds compared to conventional casting processes.The technology also supports more localized production models, which may improve supply chain resilience for large-scale metal components across maritime, energy, and defense sectors.
Source: 3D Printing Industry
