World’s First 3D-Printed Monolithic Catamaran Produced In Just 160 Hours

Caracol, an industrial 3D printer manufacturer, along with the V2 Group, a large-format additive manufacturing provider, have developed the world’s first 3D-printed monolithic catamaran, which can sail in open waters.

The 6 m-long catamaran was generated in a single print using the Heron AM robot platform.

It took almost 160 hours to print the entire design, weighing 1200 kilograms and measuring 5000 x 2300 x 1500 mm.

In the production process, researchers recorded a 30% reduction in waste production and a 20% lead time reduction.

The 3D Printing System

The printing system, called the Heron 400, used a High Flow Extruder with a nozzle size of 8 mm.

The material used was rPP + 30% GF, a composite material designed to balance structural performance with environmental sustainability.

rPP (Recycled Polypropylene) is a thermoplastic polymer sourced from post-industrial or post-consumer waste. Inorganic glass fibres are added as a reinforcement agent. At a 30% concentration, these fibres transform the flexible plastic into a high-strength engineering material.

The company plans to scale and industrialise the boat’s design, something which will be easy to achieve given the research done on understanding every stage from choosing the design, to the right kind of material for meeting the standards of the shipping industry and adhering to the international rules and regulations.

Large-format additive manufacturing robotic systems have transformed the shipping industry by offering benefits such as extremely customisable designs, appropriate use of material, which reduces wastage compared to traditional shipbuilding, and a reduction in harmful emissions.

The Visionary Project

This project was envisaged to help lay the foundation for the future industrialisation of such 3D-printed vessels.

Every stage of production was carefully analysed, and results were recorded to scale production efficiently, in a way that is both sustainable and economically viable. This is important to turn the tech into a widely applicable solution for the maritime sector.

The first 3D printed catamaran capable of sailing in open waters is the best example of how emerging additive manufacturing processes can speed up production times, reduce wastage of raw materials and enable the construction of strong and durable maritime infrastructure which can be customised to suit the needs of the global market.

Production Method

Since the catamaran was produced as a single monolithic design, using continuous additive manufacturing, it eliminated the need for large-scale assembly of critical components and also enhanced its structural integrity.

Before going forward with the print, the team conducted several tests to produce complicated sections of the boat, focusing on areas with complex reinforcements and multiple layers to ensure optimum performance and perfect print.

The slicing stage and designing stage took considerable time due to the boat’s size and dimensions. However, these are one-time preparatory steps which can be replicated in future prints of the same model, reducing preparation time for subsequent builds.

This shows that large-format additive manufacturing can be very useful for building maritime vessels, given that the technology is further developed.

What does it entail for the maritime industry?

This achievement has inaugurated a new era in manufacturing boats and nautical components using robotic printing technology, which reduces the dependence on a human workforce.

Though conventional methods of mass production of vessels use inexpensive and fast solutions such as polyester and fibreglass lamination, the industry is gradually shifting towards tailor-made, small batch production. Hence, additive manufacturing in this regard does away with the use of molds, enabling quick design replications.

Companies are researching ways to develop recyclable hulls, which will be a milestone for the sector, striving to reduce its carbon footprint and toxic waste generation.

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