A Passive Air Lubrication System (PALS) is a maritime efficiency technology used on ships. It reduces frictional resistance between the hull and the surrounding water, which in turn cuts fuel consumption and emissions. It reduces drag by releasing microbubbles beneath a ship’s hull, creating an aerated layer that cuts fuel consumption and emissions.
Armada Technologies, a maritime and energy-efficiency company focused on shipping decarbonisation, recently relied on additive manufacturing to produce an ejector for one of these systems.
This critical part features a precision geometry exposed to extreme pressures, corrosive seawater, and continuous flow. This poses a major manufacturing challenge. In general, traditional air lubrication systems rely on energy-hungry compressors. Armada’s design uses the vessel’s own forward motion to draw air through a proprietary venturi ejector.
Manufacturing an ejector with SLS and PA12 nylon
To achieve the required internal features, surface uniformity, and environmental durability, Armada worked with 3D printing service bureau 3D People to manufacture its production parts. The service bureau produces the components using SLS 3D printing and PA12 Nylon. The material was selected for its mechanical strength and durability, key requirements for this marine application. The bureau then finishes the parts using a vapour smoothing process. This creates an optimal surface interface for the fluids flowing through them.
Over four production batches, every part met Armada’s tight timeline and quality thresholds. Eight months after installation, the components continue to operate flawlessly.
“3D People stood out immediately,” said Armada COO Roger Armson. “They understood the complexity of the part, grasped our technical needs quickly, and delivered prototypes that met our stringent functional and compliance requirements.”
Other potential applications within PALS
Beyond the ejector, several other components of a Passive Air Lubrication System (PALS) are well suited to additive manufacturing. This is particularly true where complex internal geometries, fluid control, corrosion resistance, and weight reduction are critical. These components may include air distribution manifolds, internal ducting and air channels, as well as protective housings and covers, among others.
It would be interesting to see how Armada continues to advance its additive manufacturing journey as the technology matures within its PALS development roadmap.
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