A section of a next-generation marine propeller blade has been successfully 3D printed as part of the Digitally Enabled Efficient Propeller (D.E.E.P) project, a seven-month feasibility program exploring additive manufacturing for maritime propulsion. The component was produced using wire arc additive manufacturing (WAAM) in Nickel Aluminium Bronze (NAB), with the milestone marking progress toward lighter, more efficient, and digitally integrated ship propulsion systems.
The project is led by Enki Marine Ltd, a marine engineering company focused on propulsion system integration and commercialization, and brings together partners including DEEP Manufacturing Ltd, Stone Marine Propulsion, TWI, Authentise, ASTM International, and Newcastle University. The consortium spans expertise in design, materials testing, digital workflows, certification, and hydrodynamic validation.
WAAM propeller development targets performance and manufacturing constraints
The D.E.E.P project is investigating how additive manufacturing can address limitations associated with traditional casting processes for marine propellers. Conventional methods can restrict design flexibility and limit performance gains , particularly in relation to geometry and material distribution.
The WAAM-based approach enables structurally and hydrodynamically optimized blade geometries. According to the project team, this can support reduced weight and improved hydrodynamic performance, while also allowing for the integration of digital monitoring capabilities.
The propeller blade design is being developed with the potential to incorporate real-time data collection, with the potential to enable vessels to monitor propulsion performance and adjust operational parameters such as engine power and speed. This approach could also support predictive maintenance strategies and autonomous optimization of propulsion systems.
Scaling WAAM for large-format maritime components
DEEP Manufacturing Ltd, a UK-based specialist in wire arc additive manufacturing and hybrid manufacturing for high-integrity structures, is responsible for manufacturing and production scaling within the project. The company is also expanding its international WAAM capabilities, including recent operations growth in Houston, Texas.
According to DEEP Manufacturing, WAAM offers potential lead time reductions of up to two thirds compared to conventional casting processes.The technology also supports more localized production models, which may improve supply chain resilience for large-scale metal components across maritime, energy, and defense sectors.
“This is the point where digital ambition becomes physical reality. We are not simply printing a propeller, we are demonstrating a new way of thinking about propulsion design, production and long-term resilience,” said Peter Richards, CEO of DEEP Manufacturing Ltd.
Next steps toward full-scale validation
Following the production of the propeller blade section, the next phase of the D.E.E.P project will focus on scaling the technology to a full-size propeller. This will include planned sea trials and the continued development of an operational optimization platform.
The project is also evaluating multiple additive manufacturing approaches, including laser-based directed energy deposition (DED) and powder bed fusion (PBF), alongside WAAM. Simulation, mechanical testing, and lifecycle analysis are being conducted to assess performance, manufacturing efficiency, and potential reductions in greenhouse gas emissions and underwater radiated noise.
Backed by funding from Innovate UK, part of UK Research and Innovation (UKRI), the D.E.E.P project is positioned as a feasibility study supporting the development of digitally enabled shipbuilding and clean maritime technologies.
WAAM scales toward industrial deployment in high-integrity sectors
Large-format metal additive manufacturing systems based on WAAM are increasingly being used for production of high-integrity components, particularly in sectors such as defense, energy, and subsea engineering. Recent developments include the expansion of DEEP Manufacturing Ltd’s large-scale WAAM operations into the United States, where the company established a new facility in Houston to support demand for additively manufactured metal structures.
Deployment of WAAM systems in operational environments is also advancing, with AML3D installing its largest ARCEMY platform at a U.S. Navy additive manufacturing center of excellence. The system is intended to produce large-scale, high-performance metal components for defense applications, with the aim of achieving qualification for safety-critical applications.
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Featured image shows WAAM 3D printed metal propeller. Image via DEEP Manufacturing.
