• 2017 September 12 08:34

    3D printed ship’s propeller takes step closer to completion

    A prototype of the world’s first class approved ship’s propeller has been produced using 3D printing techniques. The 1,350mm diameter propeller – named WAAMpeller – is the result of a cooperative consortium of companies that includes DAMEN Shipyards Group, RAMLAB, Promarin, Autodesk and Bureau Veritas.

    The WAAMpeller was fabricated from a Nickel Aluminium Bronze (NAB) alloy at RAMLAB (Rotterdam Additive Manufacturing LAB) in the Port of Rotterdam. The propeller was produced with the Wire Arc Additive Manufacturing (WAAM) method using a Valk welding system and Autodesk software. The triple- blade structure uses a Promarin design that is used on Damen’s Stan Tug 1606. With production complete, the WAAMpeller will be CNC milled at ‘Autodesk’s Advanced Manufacturing Facility in Birmingham, UK’.

    This prototype 3D printed propeller represents a steep learning curve of the understanding of material properties. “This is because 3D printed materials are built up layer by layer,” says Kees Custers, Project Engineer in Damen’s R&D department. “As a consequence, they display different physical properties in different directions – a characteristic known as anisotropy. Steel or casted materials, on the other hand, are isotropic – they have the same properties in all directions.”

    Because of this critical difference, one of the first steps was to carry out extensive testing of the material properties of the printed material to ensure compliance to Bureau Veritas standards. “This involved printing two straightforward walls of material – then using a milling machine to produce samples for lab testing of tensile and static strengths.” It can also be said that the 400kg WAAMpeller sets a milestone in terms of 3D printing production techniques.

    “The challenge has been to translate a 3D CAD file on a computer into a physical product. This is made more complex because this propeller is a double-curved, geometric shape with some tricky overhanging sections,” explains Mr Custers. Yannick Eberhard from Promarin’s R&D department adds that “the transformation from a semi-automatic to robotic processing is the solid foundation for even more complex and reliable future propeller designs“.

    “Material characterization and mechanical testing have been an important part of this project,” says Wei Ya, Postdoctoral Researcher from the University of Twente at RAMLAB. “We have to make sure that the material properties meet the needs of the application. Material toughness, for example – ensuring that the propeller is able to absorb significant impact without damage.”

    “But we have also been working towards optimising the production strategy for 3D metal deposition. This includes bead shape and width, as well as how fast we can deposit the printed material.” Highlighting RAMLAB’s capacity to print objects with maximum dimensions of 7x2x2 metres, Mr Ya says: “For large scale 3D metal deposition, the WAAMpeller is really ground-breaking for the maritime industry.”

    “This technology is a fundamental change in the concept of how we make things. With additive manufacturing, you can print most metallic components that are needed in principle. There is so much potential for the future – these techniques will have a big impact on the supply chain.” Class approval This first prototype WAAMpeller will be used for display purposes, and planning for a second example is already underway.

    “We start production of a second propeller with class approval later next month –  using all the lessons we have learned over the past few months,” notes Mr Custers. “We are aiming to install this second one onto one of our tugs later this year.” 

    Damen Shipyards Group

    Damen Shipyards Group operates 33 shipbuilding and repair yards, employing 9,000 people worldwide. DAMEN has delivered more than 6,000 vessels in more than 100 countries and delivers some 180 vessels annually to customers worldwide. Based on its unique, standardised ship-design concept DAMEN is able to guarantee consistent quality. Damen’s focus on standardisation, modular construction and keeping vessels in stock leads to short delivery times, low ‘total cost of ownership’, high resale values and reliable performance. Furthermore, DAMEN vessels are based on thorough R&D and proven technology. DAMEN offers a wide range of products, including tugs, workboats, naval and patrol vessels, high speed craft, cargo vessels, dredgers, vessels for the offshore industry, ferries, pontoons and superyachts. For nearly all vessel types DAMEN offers a broad range of services, including maintenance, spare parts delivery, training and the transfer of (shipbuilding) know-how. DAMEN also offers a variety of marine components, such as nozzles, rudders, anchors, anchor chains and steel works. DAMEN Shiprepair & Conversion (DSC) has a worldwide network of sixteen repair and conversion yards of which twelve are located in North West Europe. Facilities at the yards include more than 50 floating and (covered) drydocks, the largest of which is 420 x 90 metres, as well as slopes, ship lifts and indoor halls. Projects range from the smallest simple repairs through Class’ maintenance to complex refits and the complete conversion of large offshore structures. DSC completes around 1,350 repair and maintenance jobs annually, both at yards as well as in ports and during voyage.




2018 October 20

08:47 Boskalis, Van Hattum en Blankevoort and Mobilis construct deep-sea quay for the new HES Hartel Tank Terminal at Maasvlakte
08:10 Navios Partners announce filing of F - 1 for direct listing of Navios Containers
08:06 Maersk Line increases FAK rates for Northern Europe to Middle East and ISC trade
08:04 U.S. Navy contracts Austal to order materials for EPF 13
07:44 EU Commission launches the European Network of U-space Demonstrators

2018 October 19

18:42 ABN AMRO, Samsung SDS and the Port of Rotterdam Authority launch container logistics blockchain pilot
18:07 Stena Line's battery hybrid vessel completes its first month of operation
17:56 ABN AMRO, Samsung SDS and Port of Rotterdam Authority launch container logistics blockchain pilot
17:35 Port of Gdansk participated in the CILF 2018 fair in China
17:11 Gdansk pays a visit to Singapore
16:57 Testbed established for Internet of Ships Open Platform
16:48 Finland’s Water Transport Act aims to improve safety and increases preparedness for the future
16:26 World’s largest LNG bunker supply vessel “Kairos” started its voyage to Europe
16:04 KN will motivate its employees with the company's shares
15:42 New Falck training centre on the Maasvlakte officially openes
15:20 Seimas members visiting Klaipėda discussed benefits provided by LNG terminal
14:59 Ukraine plans dredging of 16.33 million cbm of material in 2019
14:37 UN agencies delivering on maritime security
14:15 Hapag-Lloyd starts new Red Sea service
14:00 Atomflot: shipments from Arctic LNG and Yamal LNG to be assisted by diesel and gas powered icebreakers
13:31 MOL's newbuilt LNG carrier "MARVEL EAGLE" to transport LNG from Cameron project in U.S.
13:11 NIBULON Shipbuilding and Repair Yard launches POSS-115 Project tug
13:05 BigLift Barentsz sails Northern Sea route for Pioneering Spirit
12:48 Glavgosexpertiza approves reconstruction of KSK grain terminal to increase its capacity to 4 million tonnes
12:22 Q&A with ImageSat International released ahead of SMi’s 4th annual Maritime Reconnaissance and Surveillance Technology conference
12:05 FESCO wins tender for supplying Indian Research Stations in Antarctica in 2019
11:43 Competition for designing and construction of LNG-powered icebreaker to be announced in late 2018 - early 2019
11:20 North Sea Giant turns to The Switch EBL technology
10:54 NOVATEK to place four FLNG facilities on the Northern Sea Route
10:31 RF Navy’s major amphibious ship Ivan Gren enters North Sea
10:07 Port of Vancouver closes 2018 cruise season
09:56 Brent Crude futures price up 0.4% to $79.61, Light Sweet Crude – up 0.35% to $68.89
09:38 Tackling maritime emissions - IMO rolls out ship and port toolkits
09:29 Expert forecasts more favorable ice situation on Northern Sea Route for 30 years ahead
09:15 Baltic Dry Index is up to 1,565 points
09:07 Hapag-Lloyd, CMA-CGM and COSCO enhance GEM service - covering Mediterranean with the Middle East / ISC
08:37 Samskip launches Netherlands-Italy multimodal rail service
08:07 SEA\LNG submits open comment on the draft supplemental environmental impact statement for Puget Sound LNG facility
07:20 Van Oord awarded offshore contract for the West White Rose Project

2018 October 18

18:03 VSDV opens new crossdock location in the port of Amsterdam
17:33 The first vessel in Klaveness Combination Carriers next generation of combination carriers named at New Yangzi Shipyard in China
17:17 Cargo transportation via Northern Sea Route can reach 17 million tonnes in 2018
17:03 Savannah container trade up 12 percent in September 2018
16:55 PGRK: sales strategy of Pavlovskoye deposit project is focused on foreign markets
16:33 SITC Logistics Group signs strategic cooperation agreement with Chengdu Port Investment Group and Guangzhou Port Logistics Group
16:03 NYK and Horiba to develop a new sulfur-in-oil analyzer for ships
15:34 Thames freight volume rises by 40% as Thames Vision strategy starts to bear fruit
15:33 Port of Rotterdam Authority and research institute TNO present results of the study at IMO meeting
15:31 Dublin Port volumes grow by 4.7% in first nine months. By year end, 36% growth in just six years
15:03 Chinese Lingang group invests 85 million euros in Zeebrugge inner port
14:47 Practical aspects of LNG bunkering to be discussed at the dedicated conference in Moscow on October 24
14:33 Nouryon, Tata Steel, and Port of Amsterdam partner to develop the largest green hydrogen cluster in Europe
14:24 Bunker prices may change irregular next week amid rising volatility on global fuel market, expert says
14:11 Tallink and Rauma marine constructions sign letter of intent for the construction of new shuttle ferry
14:02 VesselMan and DNV GL team up to offer optimized solution for dry-docking management
13:30 Project Forward paves the way for meeting IMO’s reduction on CO2 emissions
13:14 Equinor’s share saving plan allocates shares
13:02 Damen Shipyards Group and Abu Dhabi Ports sign contract for two Damen ASD Tugs 2411
12:52 Volumes transported by TransContainer’s flatcars and containers grew by 5.1% Y-o-Y to 1.38 million TEUs
12:43 Diana Shipping announces direct continuation of time charter contract for M/V Astarte with Glencore