Maritime

Additive Manufacturing in the Maritime Industry

Leverage the advantages of additive manufacturing in the maritime sector to optimize production and respond rapidly to operational challenges in any environment.

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Additive Manufacturing in the Maritime Industry

Challenges

What does the maritime industry demand – and what is our solution

Durability

3D printing increases the durability of maritime components by enabling the use of specialized materials and optimized designs that outperform conventional manufacturing methods. Additive manufacturing allows the precise deposition of corrosion-resistant materials such as robust polymers like Nylon PA12 or ASA. These materials form protective barriers against saltwater, UV radiation, and mechanical wear, offering superior resistance to corrosion and mechanical stress compared to cast or machined components, where it is more difficult to achieve uniform material properties across complex shapes. Unlike traditional subtractive processes, which can introduce weaknesses through machining stresses or excessive material removal, the layer-by-layer manufacturing of 3D printing minimizes internal defects and improves overall structural integrity.

Weather Resistance

3D printing optimizes the weather resistance of maritime components by using UV-stable and hydrophobic materials that withstand long-term weathering better than conventionally manufactured components. Materials such as ASA, Nylon PA12, and polypropylene offer inherent resistance to UV radiation, moisture, temperature fluctuations, and salt-laden air, retaining their structural integrity without degradation. These materials outperform metals susceptible to pitting corrosion, as well as plastics that can become brittle under sunlight, as is the case with conventional casting or injection molding processes. Precise layer bonding in 3D printing processes such as FDM or SLA produces low-porosity surfaces that repel water and resist erosion from wind-driven rain or waves. Optimized geometries additionally reduce stress concentrations, extending service life compared to machined components where tool marks and surface irregularities can reduce weather resistance. Post-processing techniques such as annealing or protective coatings further improve barrier properties by sealing microstructures against moisture and chemical influences.

Weight Optimization

3D printing enables weight optimization of maritime components by creating complex, topology-optimized geometries that reduce material usage while maintaining or improving structural strength. This reduction in component weight contributes to a lower overall vessel mass, which in turn reduces fuel consumption and emissions. Topology optimization software allows engineers to design components with minimal material in non-critical areas, achieving weight savings of 24–53% in components such as bilge pump foundations or winch brackets. These lighter components retain the necessary strength through internal lattice structures that would be difficult or impossible to produce with traditional casting or machining methods. Additive manufacturing also improves material efficiency, as only the material actually needed is deposited, minimizing waste compared to subtractive techniques. The performance benefits of weight optimization are significant: lighter vessels can reduce steel consumption in a fleet by up to 16%, saving millions of tons of material while simultaneously improving hydrodynamic efficiency.

Design Flexibility

Design freedom plays a central role in the maritime industry. Whether for weight optimization, personalization, safety improvement, or much more – maximum performance is impossible without design freedom. Traditional manufacturing methods reach their limits quickly, particularly with very complex designs. Additive manufacturing, on the other hand, offers exceptional freedom in both design and production, enabling the manufacture of highly complex and intricate geometries that are difficult or impossible to realize with conventional manufacturing methods. Advanced features such as honeycomb and lattice structures, internal channels and cavities, freeform surfaces, and optimized internal architectures can be produced with precision and efficiency through 3D printing. This design flexibility allows engineers to improve structural performance, reduce weight, and tailor components to specific functional requirements without compromising manufacturability.

Large End-Use Parts

Stratasys® ASA offers a combination of mechanical and thermal properties that are excellently suited for demanding maritime applications. Technical data sheets provide detailed performance values for various print orientations, enabling precise engineering assessment. Maritime specifications are further enhanced by outstanding UV resistance: after UV exposure, tensile strength remains at 30.3 MPa, making it ideal for end-use parts exposed on deck. Low shrinkage and compatibility with large-format printers such as the Stratasys® F900 enable components with layer heights of up to 0.020 in., allowing precise and reliable maritime components to be produced.

Properties

Tensile Strength: 33 MPa (XZ orientation: 32.8 MPa; ZX orientation: 28.3 MPa)
Flexural Strength: 61.5 MPa (XZ orientation: 61.5 MPa; ZX orientation: 51.0 MPa)
Heat Deflection Temperature (HDT at 0.46 MPa): 98°C

Use cases

Protective housings up to 1 m in length for maritime electronics
Custom distributors or fairings
Brackets and fasteners
Outdoor applications

End-Use Parts

Stratasys® High Yield PA11 is an engineering-grade Polyamide 11 powder processed via Selective Absorption Fusion (SAF™) on the H350™ 3D printer, enabling the production of high-volume, impact-resistant end-use parts. This bio-based material is 100% derived from sustainable castor oil and offers excellent ductility, ideal for demanding applications requiring high nesting density and component consistency. Combined with chemical smoothing, PA11 parts achieve improved surface quality and reduced roughness for functional prototypes and housings.

Properties

Tensile Strength: 51 MPa (XZ/YX orientation) or 47 MPa (ZX orientation)
Elongation at Break: 30% (XZ/YX orientation) or 11% (ZX orientation)
Heat Deflection Temperature (HDT at 0.45 MPa): 185°C

Use cases

Sealable housings
Fluid distributors or valves
Impact-resistant covers
Shock-resistant dust extraction components
Housings with clip functions and film hinges

Carbon Fiber Layup Tooling

ULTEM™ 1010 is a high-performance thermoplastic polyetherimide (PEI) that is widely used in the maritime industry for critical components such as engine housings, structural brackets, instrument panels, and tools for composite laminate manufacturing. Thanks to its excellent thermal stability, mechanical strength, and dimensional accuracy, it is ideal for parts exposed to high temperatures, continuous mechanical stress, and harsh marine environments.

The material has a high glass transition temperature (Tg) of 217°C and can be used continuously at up to 170°C, allowing it to maintain structural integrity under the heat generated by engines, electronics, or sun-exposed decks. With a heat deflection temperature (HDT) of 216°C at 0.45 MPa, ULTEM™ 1010 maintains its dimensional stability even under prolonged thermal load.

Mechanically, it offers a tensile strength of 64 MPa (XZ orientation) and 42 MPa (ZX orientation), and a tensile modulus of 2.5–2.92 GPa, providing an excellent balance between strength and flexibility. Its flexural strength of 77–144 MPa (depending on orientation) and flexural modulus of 2.2–2.8 GPa ensure high resistance to bending and deformation, making it suitable for structural supports and tooling used in the production of composite hulls or decks.

Thanks to its durability, heat resistance, and dimensional accuracy, ULTEM™ 1010 is a reliable choice for maritime components that must withstand the combined challenges of saltwater exposure, mechanical stress, and elevated operating temperatures.

Properties

Tensile Strength: 64 MPa (XZ direction) / 42 MPa (ZX direction)
Elongation at Break: 1.1–4.0%
Heat Deflection Temperature (HDT) @ 0.45 MPa (66 psi): 216°C (421°F)

Use cases

Vacuum or Autoclave Tooling
Drill Guides
Structural Brackets
Tools

Fixtures and Brackets

Stratasys PA12 GF (glass-fiber reinforced Polyamide 12) is a high-performance SAF™ material that is exceptionally well suited for fixtures and brackets (jigs and fixtures) in the maritime industry. The combination of glass fiber reinforcement and the inherent properties of PA12 makes this material an ideal choice for demanding manufacturing environments in shipyards and maritime production facilities. With a heat deflection temperature of over 150°C, the material can be used without issues in environments where welding operations or thermal processes take place nearby. The low moisture absorption of PA12 prevents dimensional changes even in the humid conditions of shipyards.

Using SAF™ technology, complex jigs and fixtures can be manufactured as single parts, eliminating assembly effort and significantly reducing lead times. The high nesting density enables the cost-effective production of multiple fixtures simultaneously. Compared to metallic alternatives, PA12 GF reduces the weight of fixtures by up to 70%, making handling easier and providing ergonomic benefits for shipyard workers.