World’s first Class approved 3D printed ship’s propeller unveiled
Following a rigorous testing process, verified by Bureau Veritas, the world’s first Class approved 3D printed ship’s propeller, the WAAMpeller, has been unveiled at DAMEN Shipyard Group’s headquarters in the Netherlands. This ground-breaking success is the result of a close collaboration between RAMLAB, Promarin, Autodesk, Bureau Veritas and Damen, DAMEN said in its press release.
The five-company partnership started pooling their collective resources and knowledge to develop the world’s first 3D printed ship’s propeller seven months ago. Promarin provided the design of the triple-blade propeller. The Port of Rotterdam’s RAMLAB (Rotterdam Additive Manufacturing LAB) carried out fabrication using Wire Arc Additive Manufacturing (WAAM) techniques, supported by Autodesk’s expertise in software, robotics and additive manufacturing.
Damen provided Research and Development resources in addition to one of its Stan Tug 1606 vessels for operational testing purposes. Bureau Veritas’ role was to verify the entire development, production and testing process.
The consortium reached its first milestone in August with the completion of the first WAAMpeller prototype. With valuable experience gained, production of the second version, with the aim of achieving class certification, started immediately.
“Production of the second WAAMpeller was greatly improved because we had learned a lot from producing the prototype,” says Vincent Wegener, Managing Director RAMLAB. “This mainly concerned the hardware/software interaction because, when laying down 298 layers of Nickel Aluminium Bronze alloy, it is important to have a tight control on all process parameters.”
With the second WAAMpeller complete, the project then progressed to the testing stage, the first phase of which saw the WAAMpeller installed on a DAMEN Stan Tug 1606. “This particular vessel is of extra interest in that it is equipped with a Tier III compliant engine, making it future proof for the ever stricter environmental rules and regulations in harbours around the world”, comments Martin de Bruijn, Managing Director Workboats at Damen.
Damen’s testing engineers performed operational testing of the WAAMpeller on 20 November, with representatives from all of the consortium partners present. Furthermore, the day’s procedures were overseen by Bureau Veritas surveyors throughout.
Martijn Nieuwenhuijs, Chief Executive of Bureau Veritas Marine & Offshore Netherlands comments: “Bureaus Veritas has witnessed every step of the making and testing of the WAAMpeller. Some challenges needed to be tackled along the way, but the final product is technically sound and ready for commercial application.”
The testing programme included bollard pull and crash stop testing in addition to speed trials. “Of course, we were all a bit nervous beforehand – after all, innovation always comes with a certain amount of unknowns – but the testing was a success,” says Kees Custers, DAMEN Project Engineer R&D enthusiastically.
“We are pleased to report that the WAAMpeller displayed the same behaviour as a conventional casted propeller in all of the tests. This includes the same level of performance in the crash stop scenario, which – going from full throttle ahead to full throttle reverse – is the heaviest loading that a propeller can experience.
“From day one, this project has been characterised by a good working atmosphere and team dynamics, so there were quite a few high-fives on board when we had successfully completed the tests!”
Talking before the WAAMpeller unveiling event, which took place on 30 November, Allard Castelein, CEO Port of Rotterdam took the time to highlight the efforts of the collaborating partners: “The WAAMpeller project is special for many reasons. Not only has it produced the world’s first class approved 3D printed ship’s propeller, but this has been accomplished within a very impressive seven-month timeframe and only one year after the official opening of RAMLAB.”
“Everyone involved has worked extremely hard to make this happen. Damen, Autodesk and Bureau Veritas have supported the project all the way. Promarin have really shown their expertise with the finishing of this WAAMpeller. And last, but not least, the production process at RAMLAB continued 24/7, with their experts permanently on hand.”
Looking at the bigger picture, Mr Castelein went on to identify the implications of the WAAMpeller project on the maritime industry. “This project has shown the shipbuilding industry the potential of 3D printing techniques for the production of vessel components. We continue our intensive research into this very exciting area.”
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.
