From Naval Architecture to 3D Printing

My LinkedIn network has grown significantly since I shifted to 3D printing, but what many of my followers may not know is that I began my career as a naval architect. During my career, I specialized in engineering design, structural analysis, simulation, and optimization of lightweight structures made of composite materials. This included weight calculations, stability assessments, ship theory, risk analysis for flammable structures, and compliance with industry standards. During this time, I worked on the engineering and design team for several mega yachts, played a key role in the creation and optimization of an entire family of sailing yachts for a renowned German manufacturer, and contributed to various technical ship projects, or even cruise liners.

So, why did I transition into 3D printing?

While working on various applications of composite materials in the maritime sector, I began exploring 3D printing. I quickly realized the strong connection between the capabilities of 3D printing and the specific needs of producing composite structures—especially for unconventional designs that are difficult to integrate into traditional mass production. This sparked my journey deeper into the 3D printing industry. I built a strong network across both fields, which eventually led to the creation of my own company.

I’ve always believed that smart engineering can achieve fast, cost-effective results by integrating semi-experimental technology into real production processes. At 3Dock, we've always taken the most pragmatic approach, providing real solutions while leaving the insurmountable theories to others with better funding. From there, many interesting projects began to emerge, particularly in the maritime industry. Although the vast majority of our work (around 90%) is done under NDA, I can share a couple of projects initiated on our own as proposals for clients.

One project involved the need to produce small batches of rudders. We developed a preliminary design to assess the feasibility of producing a stainless-steel rudder blade using WLAM (Wire Laser Additive Manufacturing) technology, a technology that is part of the DED (Directed Energy Deposition) family. The design aimed to work within the limits of support-free printing.

Of course, CNC post-processing of the surface would still be necessary. Completing such a project would require at least two more iterations, along with testing the mechanical properties of samples made under the same conditions. The key challenge here is gaining approval from a classification society, which I’ll touch on later.

Another interesting project, which unfortunately didn’t go into production, was the study of creating a competition foil in aluminum, printed in a single piece using WAAM (Wire Arc Additive Manufacturing) technology. The foil was intended to replace a carbon fiber epoxy-injected autoclaved foil—essentially the gold standard in composite applications today. WAAM structures have quasi-isotropic properties, but its anisotropy can be simulated accurately in a model. In a conservative approach, we opted for a worst-case scenario regarding basic mechanical properties.

However, after consulting two of the top global suppliers of robot-based WAAM technology (the only solution capable of handling a structure this large), we were informed that such a slender body had a high risk of thermal deformation, so the project was abandoned.

Beyond these, we worked on various initiatives to produce spare parts for the maritime industry using 3D printing. This isn't groundbreaking, as some companies already offer digital warehousing and on-demand production via 3D printing, though much of the practical application remains limited to sectors like rail. Whether this approach solves supply chain issues remains to be seen, and I’d like to expand on that in a future article. In our case, we were developing specialized solutions for the maritime sector, where the form, deployment methods, and regulatory structure demand specific solutions. For instance, we reverse-engineered and produced a discontinued part, delivering it within a week—a pleasant surprise for our potential clients. Here’s an example of a custom-designed marine water filter (aka strainer), produced using FDM (Fused Deposition Modeling) technology, as a replacement for a stainless-steel equivalent.

In this other example, the project involved scanning an obsolete winch crown, reconstructing it, and producing it in aluminum using SLM (Selective Laser Melting) technology.

That’s a brief overview of our work in the maritime sector. There are many other applications I believe in that aren’t covered here. However, the slow pace of adaptation and decision-making in the industry prompted us, as a startup, to pivot toward other sectors where 3D printing was more established. Today, we successfully serve companies in various fields, including deep-tech startups, electronics manufacturers, the automotive sector, and, of course, the maritime industry.

So, what’s the role of a naval architect in this business?

Well, here’s my advice to anyone looking to start their own company and being innovative: listen, understand, ignore conventions, and act from day one.

We offer a specific and unique 3D printing service model, but we also continue to provide high-level engineering services. While our 3D printing service is a major focus, it basically acts as a cross-selling tool. We provide consulting services for complex design applications, working with 3D scan meshes on objects ranging from a few centimeters to superyachts. We’ve recreated parts for industrial machinery, designed for injection molding in the electronics sector, and supplied thousands of injection-molded parts to highly competitive prices and lead times, among other projects. In essence, beyond 3D printing, 3Dock is the go-to partner when you need comprehensive assistance throughout the entire production process, offering A-to-Z support.

I mention all this because 3D printing should not be seen as an isolated solution. In our company and for our clients, it’s just one valuable tool in a complex production process. That’s the context in which we’re developing a unique 3D printing service to meet the real needs of the industry.

In the end, this article is a bit of a brainstorm, meant to offer a personal perspective free of generalities, and perhaps to inspire those interested in 3D printing beyond the usual clichés and buzzwords. I hope you enjoyed it!

For more insights and updates on the latest trends in 3D printing, subscribe to our newsletter here .

#3DPrinting #Innovation #Manufacturing #NavalArchitecture #AdditiveManufacturing #DeepTech