Applying WAAM to Next-Generation Marine Propellers
New NAB propeller marks huge milestone for world-leading consortium project
New NAB propeller marks huge milestone for world-leading consortium project
View the timelapse footage here.
Printing has now completed on a section of the marine propeller designed to deliver smarter, more efficient propulsion for the future of clean shipping.
This milestone reflects growing global momentum behind Wire Arc Additive Manufacturing (WAAM) and its application in producing large-scale components for demanding environments.
Part of the Digitally Enabled Efficient Propeller (D.E.E.P) project, this achievement marks a key step for a world-leading consortium backed by Innovate UK. Led by Enki Marine Ltd, the consortium includes DEEP Manufacturing Ltd, Stone Marine Propulsion, TWI, Authentise, ASTM International and Newcastle University, bringing together expertise in design, materials testing, digital workflows, certification and hydrodynamic validation.
From traditional manufacture to WAAM
Marine propellers have traditionally been produced using casting processes. While well established, these methods can constrain design flexibility, limit opportunities for performance optimisation and introduce long lead times for complex geometries.
As demand increases for more efficient, lower-emission vessels, these constraints are becoming more pronounced. There is a growing need for manufacturing approaches that enable more advanced designs while improving delivery timelines and local supply chain resilience.
Designed for optimised performance
The propeller blade has been designed with internal cavities, reducing overall weight while maintaining structural performance and stiffness - an approach that would be difficult to achieve using conventional casting methods.
These internal geometries also create space for future integration of sensors and telemetry systems. In time, this could enable real-time monitoring of propulsion performance, allowing operators to optimise efficiency, adjust operating conditions and move toward predictive maintenance strategies.
DEEP Manufacturing’s involvement
DEEP Manufacturing is responsible for the development of the manufacturing approach and the transition from design into production, applying our large-scale DED-Arc (WAAM) capability to deliver the blade geometry in Nickel Aluminium Bronze (NAB).
This work reflects a broader shift from feasibility to industrial application. As additive manufacturing moves beyond prototyping, the ability to manufacture high-integrity components locally and at scale is becoming increasingly important across maritime and other critical sectors.
What’s next
With production now complete, the propeller blade will be transported to DEEP Manufacturing’s Houston facility, where it will be showcased as part of our May launch event.
This milestone provides a real demonstration of how digitally enabled design and large-scale additive manufacturing can be applied to complex marine components, supporting the shift toward more efficient, responsive and resilient propulsion systems.
To learn more about DEEP Manufacturing’s capabilities in large-scale additive manufacturing, or to discuss a specific application, contact our team.
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