Posted: November 6th, 2023

Application of Additive Manufacturing for Spare Parts Fabrication to Support Remote Maritime Operations

Application of Additive Manufacturing for Spare Parts Fabrication to Support Remote Maritime Operations

Additive manufacturing (AM), also known as 3D printing, is a process that creates physical objects from digital models by depositing layers of material on top of each other. AM has been widely used in various industries, such as aerospace, automotive, medical, and consumer goods, for rapid prototyping, customization, and complex geometries. However, AM also has the potential to revolutionize the maritime sector, especially for remote operations that require timely and cost-effective delivery of spare parts.

The Challenges of Conventional Spare Parts Supply Chain

The maritime sector faces many challenges in maintaining and repairing its assets, such as ships, offshore platforms, and subsea equipment. These assets operate in harsh and remote environments, where spare parts are often scarce, expensive, and difficult to transport. The conventional spare parts supply chain relies on centralized warehouses, long lead times, and high inventory costs. Moreover, the spare parts are often subject to obsolescence, damage, or theft during storage and transportation.

According to a report by DNV GL , the maritime industry spends about $13 billion annually on spare parts procurement, of which 50% is related to logistics costs. The report also estimates that 50% of the spare parts are obsolete or rarely used, resulting in wasted resources and environmental impacts. Furthermore, the conventional spare parts supply chain is vulnerable to disruptions caused by natural disasters, geopolitical conflicts, or pandemics.

The Benefits of Additive Manufacturing for Spare Parts Fabrication

AM offers a promising alternative to the conventional spare parts supply chain by enabling on-demand and decentralized production of spare parts near the point of use. AM can reduce the lead time, cost, and environmental footprint of spare parts delivery, as well as improve the availability, quality, and performance of spare parts.

Some of the benefits of AM for spare parts fabrication are:

– Reduced lead time: AM can produce spare parts within hours or days, compared to weeks or months for conventional methods. This can increase the operational efficiency and availability of maritime assets, as well as reduce the downtime and revenue loss caused by unexpected failures.
– Reduced cost: AM can eliminate or reduce the need for inventory, warehousing, transportation, and logistics costs associated with spare parts delivery. AM can also enable mass customization and optimization of spare parts design, resulting in lower material consumption and waste generation.
– Reduced environmental impact: AM can reduce the carbon footprint and energy consumption of spare parts production and delivery by using less material, transportation, and storage. AM can also use renewable or recycled materials to produce spare parts that are more eco-friendly and durable.
– Improved quality and performance: AM can produce spare parts with complex geometries, high precision, and functional gradients that are difficult or impossible to achieve with conventional methods. AM can also enable digital quality control and traceability of spare parts throughout their lifecycle.

Examples of Additive Manufacturing for Spare Parts Fabrication in Maritime Sector

Several initiatives have been launched to explore the feasibility and applicability of AM for spare parts fabrication in the maritime sector. For example:

– In 2020, Berge Bulk received one of the world’s first commercial deliveries of 3D-printed spare parts for its bulk carrier Berge Mafadi . The spare parts included scupper plugs made of thermoplastic materials that were produced by Ivaldi Group, a partner of Wilhelmsen Ships Service.
– In 2021, Pelagus 3D was established as a joint venture between thyssenkrupp and Wilhelmsen to provide on-demand digital manufacturing platform for maritime and offshore spare parts . Pelagus 3D uses a secure AM fulfillment platform to connect end users with OEMs and manufacturing partners that can produce spare parts in any material.
– In 2021, DNV GL issued the first type approval for a metal AM part in the maritime industry . The part was a propeller boss cap fin (PBCF) produced by Naval Group using laser powder bed fusion (LPBF) technology. The PBCF can improve the hydrodynamic efficiency and reduce the fuel consumption of ships.

Conclusion

AM is a disruptive technology that can transform the maritime sector by providing a more efficient, flexible, and sustainable way of producing spare parts for remote operations. AM can reduce the lead time, cost, and environmental impact of spare parts delivery, as well as improve the quality and performance of spare parts. However, there are also some challenges and barriers that need to be overcome before AM can be widely adopted in the maritime sector. These include technical issues such as material selection, design optimization, quality assurance, certification standards; as well as non-technical issues such as intellectual property rights protection,