When a critical part fails on a ship out at sea, miles from the nearest port, the crew scrambles to find a solution, knowing that delays can cost millions and repairs might take weeks. In these moments, the ability to manufacture replacement parts onboard could mean the difference between a minor setback and a major operational failure.
Additive manufacturing (AM) has long been hailed as a game-changing technology in industries like aerospace and healthcare, but maritime applications have yet to achieve the same status, probably due to the unique challenges of shipbuilding and open-sea conditions. However, recent developments by an HD Hyundai Heavy Industries (HHI) consortium—that also includes the American Bureau of Shipping (ABS), Ulsan metro City, CS CAM and KITECH—signal a significant turning point for 3D printing in the maritime sector. The consortium’s containerized “3D Printing Digital Workshop” represents the leading edge of this technology, with potential implications far beyond shipbuilding.
The State of Maritime 3D Printing
Over the past decade, the maritime 3D printing sector has been maturing, albeit at a slower pace than other industries. Shipping giant Wilhelmsen, for instance, has been driving the ability to 3D print and deliver spare parts from its AM center in Singapore to seagoing vessels off the coast. In one instance, they demonstrated a low-cost quadcopter to send the components to a ship at sea.
The progress there ultimately led Wilhelmsen to partner with German engineering leader thyssenkrupp to establish a joint venture dedicated to 3D printing for maritime and beyond. Dubbed Pelagus 3D, the firm is developing an inventory of 3D printable parts for marine customers.
Meanwhile, standards bodies such as the American Bureau of Shipping (ABS) have been conducting steady research into AM for maritime, establishing standards and validating numerous 3D printed parts, critical and non-critical, large and small.
“AM has been steadily advancing over the past decade, with progress accelerating in recent years,” said Dr. Gu Hai, Vice President of Technology at ABS. “As industries worldwide prioritize digitization, decarbonization, and supply chain resilience, now is the right time for the maritime sector to embrace this technology. ABS is well positioned to support this transition, particularly as the global leader in classification services for marine and offshore assets. Our commitment to leading research and providing insights ensures we remain at the forefront of technological advancements in the marine and offshore industries.”
At the same time, all of the world’s navies have invested in 3D printing technologies. The U.S. Navy may be the most dedicated so far, having commissioned AM facilities and installing the world’s first onboard metal printer on a naval vessel, the USS Essex.
However, the latest news from HHI, the largest shipbuilder in the world, represents a tipping point for maritime AM. From developing to installing and validating onboard 3D printing, the 3D Printing Digital Workshop now stands as the world’s first commercial vessel with onboard metal AM capabilities.
HHI’s 3D Printing Digital Workshop: A Game-Changer
Unlike other industries where AM has been successfully implemented, maritime applications must contend with heavy vibrations, constant motion, and the unpredictable nature of the sea. To address these challenges, HHI launched an ambitious project in 2023, supported by the Korean government, to develop a completely integrated AM unit that could function directly aboard a vessel. This project led to the ABS-HHI consortium, bringing together key players in shipbuilding and 3D printing to validate the concept and ensure its viability.
HHI’s approach involves placing a fully operational 3D printing facility—from powder handling, to printing and post-processing—inside a shipping container that can be deployed on seafaring vessels. The printer itself includes a proprietary motion compensation system designed to counteract the rocking of a ship, ensuring stable print conditions.
“The most important technology in the 3D Printing Digital Workshop is the application of motion compensation, an inertial navigation system to counteract vibration, and humidity control,” said Mr. Hongryeul Ryu, Executive Vice President and CTO at HHI. “Our focus is to maintain the same print quality as on land.”
This innovation was rigorously tested during a recent sea trial, where the team successfully 3D printed components onboard despite the vessel’s movement. “Last month, we successfully printed the first part from the 3D printed digital workshop. It was very challenging due to heavy vibrations, but our system was able to compensate,” Mr. Ryu said. This milestone marks a significant leap in the feasibility of onboard AM.
Advantages and Implications for the Maritime Industry
One of the most immediate benefits of this technology is the reduction in lead times for critical spare parts. “Our clients typically wait 233 days for replacement components, but if our system is onboard, two days is enough to print the necessary part,” said Chulho Jang, Senior Engineer in Production Innovation Engineering at HHI. This capability could drastically reduce vessel downtime and lower logistical costs associated with transporting replacement parts from shore.
Moreover, HHI has also been working on metal powders specifically for shipbuilding applications. “The current market powder for 3D printing is mostly suited for aerospace and other high-precision industries, but it is not well-matched for shipbuilding,” Jang said. “HHI has developed a new powder specifically for shipbuilding, which was successfully printed on the vessel.” This carbon-steel material, called SS400 in maritime, is significantly cheaper than existing powders, making it a viable option for widespread adoption.
Future Expansion: A Maritime Digital Supply Chain
The company plans to roll out both of these products commercially, so that the entire marine sector can benefit from onboard 3D printing and digital inventories. HHI envisions a future where 3D printing is integrated into a global digital supply chain for ship maintenance and repair.
“Our goal is to build a network between ports and vessels so that any required component can be easily printed and received onboard,” Jang revealed. The idea is to establish digital libraries of essential components, allowing ships to order parts remotely and have them printed at nearby ports or onboard, reducing dependency on traditional supply chains.
This vision aligns with broader industry trends pushing for digitalization in maritime logistics. If successful, such a system could significantly enhance fleet readiness and operational efficiency. “If a ship is approaching a port in Singapore or Ulsan and needs specific materials, they can simply order online from the digital library, and the part will be printed at the port and picked up upon arrival,” Jang explained.
ABS Leading the Way for Qualification of Maritime 3D Printing
Classification societies like ABS play a crucial role in forward-looking initiatives such as HHI’s onboard 3D printer. Beyond establishing standards and guidelines, it is essential for classification societies to continuously refine qualification procedures to support the implementation and adoption of emerging technologies.
In the case of the ABS-HHI consortium, ABS is facilitating the early adoption and efficient integration of onboard 3D printing through its New Technology Qualification framework. This framework provides the industry with a structured approach to verifying that new technologies function as intended and meet defined performance requirements.
Additionally, ABS is working with industry leaders like HHI to streamline existing regulations and develop new guidance for a more efficient qualification and approval process. By ensuring that maritime 3D printing qualification procedures remain current and aligned with industry practices, ABS is helping to drive the adoption of the technology.
Smooth Sailing for Maritime 3D Printing
The maritime sector is often slow to adopt new technologies, but HHI’s breakthrough sees the tide turning in 3D printing’s favor.
“There is enormous potential for AM in shipbuilding and the maritime industry. We have seen a growing number of applications in maritime 3D printing, and with recent technological advancements combined with innovative business models, there are even more opportunities ahead,” said Dr. Wu Wenjin, Principal Engineer of Technology at ABS. “By fostering the right collaborations and leveraging each other’s strengths, we can work together to accelerate the adoption of 3D printing in the maritime sector.”
The success of this project could pave the way for more widespread adoption of AM across the industry. As 3D printing becomes more entrenched in maritime operations, shipbuilders and operators alike will need to adapt to the changing landscape. With reduced lead times, cost-effective materials, and a vision for a globally connected network of 3D printing hubs, ABS and HHI’s pioneering efforts may well usher in a new era for shipbuilding and maintenance.