With a growing number of fully 3D printed boat hulls emerging around the world using its technology, the Dutch large-format 3D printing company CEAD decided to establish its own internal division dedicated to maritime applications, the Maritime Application Center (MAC). Closely documenting the success of its very first project, MAC ONE, led to a full case study that proved the viability of this approach.

The boat, conceived, tried and tested by CEAD Co-founder Maarten Logtenberg (who even caught what is likely to be the first fish from a 3D printed boat), became a powerful example of what modern engineering and large-scale 3D printing technology can achieve in the marine industry. Powered by CEAD’s maritime-applications-specific Boat Hull Production Machine, this vessel demonstrated how LFAM can redefine performance, sustainability, and efficiency in the boating industry.

Logtenberg, a fishing enthusiast and marine designer, created the MAC ONE as a rugged, recyclable, and high-performance boat that can be produced faster and more affordably than traditional methods allow. Thanks to CEAD’s integrated system, which combines hardware, software, and reinforced thermoplastics, the project was executed with remarkable precision and speed. Unlike conventional boatbuilding, which often faces limitations due to flat sheet materials like aluminum, 3D printing enables the creation of complex, double-curved surfaces at no additional cost. This not only enhances the boat’s aesthetics but also improves its structural strength and hydrodynamic performance.

The boat’s construction utilizes CEAD HDPro, a high-strength thermoplastic filled with 25% glass fiber, which delivers twice the stiffness and strength of standard HDPE while maintaining a low weight. The entire hull, including impact-critical areas such as the keel and transom, was printed in just 82 hours using automated systems and patented support pins that enable overhangs to be printed mid-air without human intervention. This innovation greatly reduces the need for post-processing and increases safety during production.

Design considerations went beyond aesthetics and strength. Practical features such as a self-bailing deck, integrated fuel tanks, built-in cable gutters, and pre-printed seating areas were all incorporated directly into the 3D model. Internal structures were designed using two strategic print approaches: one focusing on thick outer shells with zigzag infill for durability, and another using dual-wall construction for greater design flexibility. These elements were made possible by CEAD’s specialized toolpath simulation software, which ensured precision and manufacturability at every step.

Once printing was completed, components such as the console and leaning post—printed separately on Flexcube machines—were welded into place using HDPro filler and thermoplastic extrusion welding. This method not only guarantees structural integrity but also ensures watertight seams and clean finishes. The final product is a durable, lightweight fishing boat optimized for both recreational and commercial use.

To explore all technical details and insights from the design to the final production of the MAC ONE, you can download the full case study in PDF format at this link.