The projects results are achieved by using large scale additive manufacturing
A project utilising large-scale additive manufacturing to produce shipbuilding components has finished its second phase, producing substantial evidence to reduce greenhouse gas emissions, secure supply chains and deliver significant economic benefits for the maritime sector
A topology-optimised tapping ring, the project's redesigned metal component, achieved a 10% reduction in emissions, a 90% reduction in lead times, and a 13% reduction in vessel weight during testing.
The project is led by Glasgow-based Malin Marine Consultants (MMC), part of the Malin Group, and supported by the National Manufacturing Institute Scotland (NMIS), which the University of Strathclyde operates.
Marine Vessel Lightweighting (MariLight) 2.0 builds on an initial feasibility study aimed at moving the sector away from traditional manual fabrication toward automated, flexible, and environmentally friendly manufacturing approaches.
Large-scale additive manufacturing supports sustainability by producing lighter, topology-optimised parts locally and on demand, minimising material waste, energy use, and emissions.
Advanced digital manufacturing techniques were utilised to improve component design and performance. A significant milestone was the successful testing of a topology-optimised tapping ring, a metal component used to reinforce openings cut into vessel decks or tanks, providing secure access points.
The redesigned part enables more efficient material utilisation, enhancing structural performance while reducing weight. It underwent hydrostatic and leak testing under sustained pressure, witnessed by project partner Lloyd's Register to ensure independent verification of the tests, a vital step towards wider sector adoption.
The tapping ring was manufactured using Direct Energy Deposition-Arc (DED-Arc) technology at NMIS's Digital Factory. This additive manufacturing process builds metal parts layer by layer using advanced welding techniques, enabling local, on-demand production of lighter, optimised components with minimal material waste.
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 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, optimising supply chain transparency using 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."
Chris Dunn, managing director of MMC, said: "MariLight 2 represented a major step forward in the validation of additive manufacturing, and its potential impact on more sustainable, efficient manufacturing methods within the maritime sector. Having Lloyd's Register present at the trials and then certify the tapping ring greatly enhances confidence in the commercial deployment of these innovative components. As a core member of the project consortium, NMIS played a key role in this, harnessing their technical expertise to manufacture an optimised tapping ring using DED-Arc technology."
Adam Saxty at Lloyd's Register added, "Additive manufacturing has enormous potential to assist shipbuilding in becoming more sustainable. As the MariLight 2 project demonstrates, the technology can manufacture highly efficient, topology-optimised components. The results of the testing completed so far are encouraging. Lloyd's Register is pleased to support the continued development of these advanced manufacturing techniques as they progress toward wider adoption in the industry."
