3D printing in shipyards and the naval industry is undergoing a period of unprecedented innovation. Digitisation, automation and the search for more sustainable processes have opened the door to technologies that previously seemed futuristic.

One of the most promising is 3D printing, also known as additive manufacturing, which allows parts and prototypes to be created layer by layer from a digital model.

For years, 3D printing was associated with research and development in laboratories. Today, however, it is being integrated into shipyards, ports and ancillary companies, bringing advantages such as reduced logistics costs, rapid manufacture of spare parts and flexibility in component design.

In this article, we will explain the available technologies, their real applications in prototypes and parts, as well as the medium-term prospects that will shape the future of shipbuilding.

1. 3D printing technologies in shipyards applied to shipbuilding

3D printing is not a single technique, but rather a set of methods that use different materials and processes. In shipyards, the most commonly used are:

a) FDM (Fused Deposition Modeling)

This method uses plastic filaments that are melted and deposited layer by layer. It is very useful for design prototypes and ship models. Its low cost and ease of use make it the gateway to additive manufacturing in the naval sector.

b) SLA (Stereolithography)

Based on photosensitive resins that solidify with lasers. It offers high precision and detailed finishes, making it ideal for small components and naval engineering tests.

c) SLS/DMLS (Selective Laser Sintering / Direct Metal Laser Sintering)

It uses plastic or metal powders fused by laser. It allows the manufacture of high-strength functional parts such as valves, casings, or engine mounts. It is one of the key technologies for real applications in shipyards.

d) WAAM (Wire Arc Additive Manufacturing)

One of the most promising for the heavy shipbuilding industry. It uses metal wire and electric arcs to construct large, strong parts such as structural sections and propellers.

🔍 Real-life example: in 2017, the RAMLAB project in the port of Rotterdam printed the first DNV-certified metal propeller for a tugboat, demonstrating the viability of this technology in maritime operations.

2. Practical applications in shipyards and ships

Beyond theory, additive manufacturing is already being applied in various areas:

a) Naval design prototypes

3D printing in shipyards involves printing scale models of ships, piping systems, or deck equipment. This allows designs to be validated, faults to be detected, and processes to be optimised before moving on to final construction. The savings in time and costs are significant.

b) Spare parts on demand

One of the greatest benefits of 3D printing is the ability to manufacture spare parts directly at the shipyard or even on board the ship. This avoids lengthy downtime when a part fails in the middle of a voyage and replacement would take weeks.

💡 Case study: The Wilhelmsen Group has launched a 3D printing service in strategic ports, reducing logistics costs and ensuring immediate availability of parts.

c) Critical metal components

Technologies such as WAAM and DMLS are used to produce highly resistant parts such as propellers, engine mounts and structural sections. Although they still require rigorous certification, there are already components in service that have been approved by classification societies.

d) Customised tools

Shipyard workers print tools specifically designed for assembly or repair tasks, increasing ergonomics and safety at work.

3. Benefits for the shipbuilding industry

The integration of 3D printing in shipyards offers multiple advantages:

• Cost reduction: less dependence on supply chains and less need to store large inventories.
• Speed: spare parts manufactured in hours or days instead of weeks.
• Sustainability: waste reduction compared to traditional machining processes.
• Flexibility: customised parts tailored to each vessel.
• Resilience: ability to produce locally in the event of global logistical disruptions.

According to Lloyd’s Register, 3D printing could reduce component delivery times to shipyards by up to 50% by 2030.

4. Current challenges and limitations

Although promising, additive manufacturing in shipyards faces challenges:

1. Parts certification: not all printed components currently meet maritime safety standards.
2. High initial costs: especially for metalworking equipment.
3. Specialised training: engineers and technicians trained in additive manufacturing are needed.
4. Scale limitations: some large parts are still not feasible to print.

The IMO and DNV are working on specific regulations to ensure the quality and safety of 3D-printed parts.

5. Medium-term outlook

The future of 3D printing in shipyards looks promising. Between 2025 and 2035, the following is expected:

• Full integration in shipyards: metal 3D printers forming part of the production chain.
• Decentralised production: spare parts printed at strategic ports, reducing dependence on distant suppliers.
• Circular economy: use of recycled materials in the printing of parts.
• Connection with digital twins: integration of 3D models with manufacturing systems, closing the loop between design, production, and operation.

📈 According to Allied Market Research, the 3D printing market in the naval sector will grow at an annual rate of 19% until 2030.

Conclusions

3D printing in shipyards has gone from being an experiment to becoming a practical reality with high-impact applications. Prototypes, spare parts and certified critical components are now part of operations in some ports and shipping companies.

Widespread adoption will depend on cost reduction, progress in certification and staff training. Shipyards and shipowners who invest in these technologies today will be better prepared to compete in a future where efficiency, sustainability and logistical resilience will make all the difference.

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