D.E.E.P consortium advances NAB marine propeller
The Digitally Enabled Efficient Propeller (D.E.E.P) consortium has marked a key milestone, demonstrating the production of a propeller blade section using Wire Arc Additive Manufacturing (WAAM) in nickel aluminium bronze (NAB), as part of a seven-month programme exploring advanced propulsion solutions for maritime applications.
Led by Enki Marine Ltd, the consortium includes DEEP Manufacturing Ltd, Stone Marine Propulsion, TWI, Authentise, ASTM International and Newcastle University, the D.E.E.P project is investigating how Additive Manufacturing can overcome the design constraints associated with conventional casting processes, which typically limit design flexibility and performance optimisation. By enabling more complex geometries, the approach aims to support the development of lighter, more efficient propulsion systems for clean shipping.
At the core of the project is a structurally and hydrodynamically optimised blade architecture. This design approach is intended to reduce weight while improving efficiency and enabling integrated data capabilities. The consortium states that, in future, such systems could allow vessels to monitor propulsion performance in real time, optimise engine power and speed, and support predictive maintenance strategies.
Time-lapse footage of the build process provides insight into the Additive Manufacturing of large-scale marine propulsion components (Courtesy DEEP)
“This is the point where digital ambition becomes physical reality,” stated Peter Richards, CEO at DEEP Manufacturing, responsible for manufacturing process development and production scaling. “We are not simply printing a propeller; we are demonstrating a new way of thinking about propulsion design, production and long-term resilience.
“As we continue to scale our WAAM capabilities internationally, including our recent expansion into Houston, [Texas,] we are seeing first-hand how demand is growing for faster, more flexible manufacturing of large-scale, high-integrity components across critical industries,” he concluded.
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The next phase of the D.E.E.P programme will focus on scaling the technology to a full-size propeller, alongside the development of a sea trial and operational optimisation platform.
