Additive Manufacturing enables innovation in the design of submarine components

Amongst others, superior product functionalities, increased system availabilities as well as more resilient logistic chains can be the result of Additive Manufacturing implementation in the maritime defense sector. Already today, Additive Manufacturing processes are widely used in the scope of submarine manufacturing as a solution for conventionally not available parts, jigs and tools or dummies.

Less weight as well as improved functionalities yet fast and flexible

Further benefits of Additive Manufacturing of designs can be weight and space reduction as well as functional integration. The geometrical freedom of Additive Manufacturing allows new design approaches not manufacturable by conventional processes anymore often allowing superior functionalities, e.g. for heat exchangers. In addition, assembly efforts often can be reduced and the need to manufacture many small components that have to be assembled individually can sometimes even be eliminated.

Selected Additive Manufacturing processes used on the yard are covered by a DNV approval of manufacturer and fully capable for functional parts. 3D printed metal components are moreover already successfully shock tested and implemented aboard.

New milestone: Fluid-Ducting Systems successfully tested aboard

In the context of current submarine projects, our specialists are producing fluid ducting components from a specifically developed metal alloy. As part of a redesign, experts from different departments collaborated with customers to align and redesign a component from the fluid-ducting system for Additive Manufacturing – from the first idea to the finished product. The 3D printed component was fully designed with Additive Manufacturing in mind considering all manufacturing restrictions and optimizing the overall manufacturing process. The redesign part facilitated functional integration with less assembly efforts and reduced space as well as post machining efforts. The component was successfully shock tested and validated aboard. Findings made are already being transferred to new follow up projects.

Impact on product lifecycle by AM is manifold 

Amongst others, benefits in the implementation of Additive Manufacturing in the product lifecycle can be improved availability, less assembly efforts and reduced lead times.

Especially for low lot sizes the tool less nature of Additive Manufacturing allows faster, flexible and often more cost-effective part realization and improved availability.

Combining all needed expertise in integrated project teams already allowed radical new designs that are now being transferred to serial production. Accomplished work includes the whole process chain from design to printing and post machining. Specific part requirements, quality inspection and certification approaches were also considered in this process.

Looking to the future

thyssenkrupp Marine Systems is the first maritime company in the world with DNV manufacturer approval for metallic 3D printing and is already using the technology for the series production of highly complex components and setting the quality standard for the industry.

Leveraging our collective expertise by working in agile teams, we will strategically design more components for 3D printing and aim to implement the technologies in dedicated business models in the future – not only for new projects but also for spare parts in order to offer our customers further service options.

For more insights into our technologies and our crew at thyssenkrupp Marine Systems, check out our stories.