DEEP Manufacturing prints WAAM marine propeller blade in NAB
Wire arc additive manufacturing applied to complex propulsion component with internal cavities, as part of project backed by Innovate UK consortium.
DEEP Manufacturing Ltd has completed the printing of a Nickel Aluminum Bronze (NAB) marine propeller blade as part of the Digitally Enabled Efficient Propeller (D.E.E.P.) project, a consortium effort backed by Innovate UK and led by Enki Marine Ltd.
The consortium, which also includes Stone Marine Propulsion, TWI, Authentise, ASTM International, and Newcastle University, draws on combined expertise across design, materials testing, digital workflows, certification, and hydrodynamic validation.
Casting is the traditional production method for marine propellers, but this well-established process places limitations and strains on important areas such as design flexibility, geometry complexities, and extended lead times. Manufacturers are becoming more and more aware of these issues as demand for lower-emission vessels grows.
The propeller blade was designed with internal cavities, which reduced overall weight while preserving structural performance and stiffness. This kind of geometry would be difficult to achieve through conventional casting.Â
The hollow architecture also creates space for the future integration of sensors and telemetry systems, which could support real-time monitoring of propulsion performance and enable condition-based maintenance strategies.
DEEP Manufacturing led on developing the manufacturing approach and managing the transition from design into production, applying its large-scale Directed Energy Deposition-Arc (DED-Arc) WAAM capability to produce the blade geometry.
The completed propeller blade is now set to be transported to DEEP Manufacturing’s facility in Houston, Texas, where it will be presented at a launch event in May 2026 as the company highlights a practical demonstration of how digitally enabled design and large-scale additive manufacturing can be applied to complex marine components, in support of more efficient propulsion systems.
The new facility is set to open next month, one year ahead of schedule, as part of the company’s $10 million US expansion.
