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As part of the “Digitally Enabled Efficient Propulsion” (D.E.E.P) project, a section of a next-generation marine propeller blade has been successfully produced using 3D printing. The seven-month feasibility study aims to explore the application of additive manufacturing in marine propulsion systems. Manufactured from Nickel Aluminum Bronze (NAB) using Wire Arc Additive Manufacturing (WAAM) technology, the component represents a major step toward lighter, more efficient, and digitally integrated propulsion systems for the maritime industry.

The project is led by Enki Marine Ltd, a marine engineering company specializing in propulsion system integration and commercialization. Project partners include DEEP Manufacturing Ltd, Stone Marine Propulsion, TWI, Authentise, ASTM International, and Newcastle University. Together, the consortium brings expertise in design, material testing, digital workflows, certification, and hydrodynamic validation.

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WAAM Propeller Development Balances Performance and Manufacturing Constraints

The D.E.E.P project is investigating how additive manufacturing can overcome the limitations of conventional marine propeller casting processes. Traditional manufacturing methods can restrict design flexibility and limit performance improvements, particularly in terms of geometry optimization and material distribution.

The WAAM-based manufacturing approach enables structurally and hydrodynamically optimized blade geometries. According to the project team, this can reduce weight, improve hydrodynamic efficiency, and support the integration of digital monitoring capabilities.

The propeller blade design also has the potential to incorporate real-time data acquisition, enabling vessels to monitor propulsion performance and adjust operational parameters such as engine power and rotational speed. This approach could further support predictive maintenance strategies and autonomous optimization of propulsion systems.

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Scaling WAAM Technology for Large Marine 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 scale-up within the project. The company is also expanding its international WAAM capabilities, including a recent business expansion into Houston, Texas.

According to DEEP Manufacturing, WAAM technology could reduce lead times by up to two-thirds compared with traditional casting methods. The technology also supports more localized production models, potentially strengthening supply chain resilience for large metal components used in maritime, energy, and defense sectors.

\"This is the moment where the digital vision becomes physical reality. We are not just printing a propeller — we are demonstrating an entirely new way of thinking about propulsion design, production, and long-term resilience,” said Peter Richards, CEO of DEEP Manufacturing Ltd.

Next Steps Toward Full-Scale Validation

Following the successful production of the propeller blade section, the next phase of the D.E.E.P project will focus on scaling the technology to full-size propellers. This includes planned sea trials and the continued development of operational optimization platforms.

The project is also evaluating multiple additive manufacturing technologies, including laser-based Directed Energy Deposition (DED) and Powder Bed Fusion (PBF), alongside WAAM. Ongoing simulations, mechanical testing, and lifecycle assessments are intended to evaluate performance, manufacturing efficiency, and the potential for reducing greenhouse gas emissions and underwater radiated noise.

The D.E.E.P project is funded by Innovate UK, part of UK Research and Innovation (UKRI), and is positioned as a feasibility study supporting the advancement of digital shipbuilding and clean maritime technologies.

WAAM Advances Toward Industrial Deployment in High-Integrity Sectors

Large-scale metal additive manufacturing systems based on WAAM technology are increasingly being adopted for the production of high-integrity components, particularly in defense, energy, and subsea engineering applications.

Recent developments include DEEP Manufacturing Ltd expanding its large-scale WAAM operations into the United States, where the company established a new facility in Houston to meet growing demand for additively manufactured metal structures.

Deployment of WAAM systems in operational environments is also progressing. AML3D has installed its largest ARCEMY platform at the U.S. Navy’s Additive Manufacturing Center of Excellence. The system is intended to produce large, high-performance metal components for defense applications, with the goal of achieving qualification for safety-critical use cases.

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D.E.E.P Project Achieves 3D-Printed A Marine Propeller Milestone

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