A project using large-scale additive manufacturing to produce shipbuilding components has completed its second phase. The results show strong potential to reduce greenhouse gas emissions, secure supply chains and deliver significant economic benefits for the maritime sector.
The project’s redesigned metal component – a topology optimised tapping ring – delivered a 10% reduction in emissions, cut lead times by 90% and reduced vessel weight by 13% in testing.
Glasgow-based Malin Marine Consultants (MMC), part of Malin Group, leads Marine Vessel Lightweighting (MariLight) 2.0. The National Manufacturing Institute Scotland (NMIS), operated by the University of Strathclyde, supports the project. It builds on an initial feasibility study aimed at shifting the sector away from traditional manual fabrication towards automated, flexible, and environmentally friendly manufacturing approaches.
Testing the redesigned tapping ring
The redesigned part allows for more efficient use of material, enhancing structural performance while reducing weight. It underwent rigorous hydrostatic and leak testing under sustained pressure. Project partner Lloyd’s Register witnessed the tests to ensure independent verification – a crucial step towards wider sector adoption.
NMIS’s Digital Factory manufactured the tapping ring using Direct Energy Deposition-Arc (DED-Arc) technology. This additive manufacturing process builds metal parts layer by layer using advanced welding techniques. This enabled local, on-demand production of lighter, optimised components with minimal material waste.
Partners and digital process support
Other project partners included BAE Systems, Caley Ocean Systems (part of the Pryme Group), Siccar, Altair, and Hexagon Manufacturing Intelligence (HMI). Altair produced the topology optimised design for the tapping ring using their design optimisation software (Altair Inspire and Altair Optistruct). HMI provided advanced computational modelling solutions, simulating the DED-Arc process and assessing factors such as temperature gradients and distortion prediction. Siccar delivered a secure data-sharing platform, enhancing supply chain transparency through data traceability and real-time access to verified information.
Misael Pimentel, MariLight 2.0 project lead at NMIS, said: “MariLight 2.0 showcases the real-world potential of large-scale additive manufacturing in the maritime sector. By combining advanced digital processes with rigorous certification protocols, we’ve demonstrated how this technology can support more sustainable, efficient production methods. This project highlights NMIS’s ability to help industry transition to cleaner, more agile manufacturing and helps Scotland progress towards net zero ambitions.”
MariLight 2.0 was funded by the Department for Transport’s Clean Maritime Demonstration Competition (Round 4) and supports the UK’s commitment to achieving net-zero maritime emissions by 2050.
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