Revolutionary onboard 3D printing system slashes parts wait times from 233 days to just 2, transforming ship maintenance at sea.
When a critical part fails on a ship out at sea, miles from the nearest port, delays can cost millions and repairs might take weeks. Now, a groundbreaking solution from HD Hyundai Heavy Industries (HHI) and the American Bureau of Shipping (ABS) is changing the game for maritime operations.
The consortium’s containerized “3D Printing Digital Workshop” represents the world’s first commercial vessel with onboard metal additive manufacturing capabilities, a development that signals a significant turning point for 3D printing in the maritime sector.
In contrast to other sectors where additive manufacturing has proven effective, maritime applications must overcome heavy vibrations, constant motion and the unpredictable nature of the sea. HHI’s approach places a fully operational 3D printing facility inside a shipping container that can be deployed on seafaring vessels.
“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 quite difficult because there were strong vibrations, but our system compensated for this,” Mr. Ryu said.
Classification societies like ABS play a crucial role in these forward-looking initiatives. Through its New Technology Qualification framework, ABS is enabling early adoption and integration of onboard 3D printing and giving the industry a structured method for ensuring that new technologies do what they are intended to do.
“There is enormous potential for AM in shipbuilding and the maritime industry,” said Dr. Wu Wenjin, Principal Engineer of Technology at ABS. “Together we can speed up the use of 3D printing in the maritime industry with the right partners and combining each other’s strengths.”
The maritime sector is often slow to adopt new technologies, but HHI’s breakthrough sees the tide turning in 3D printing’s favor, with implications far beyond shipbuilding.
