London Maritime Academy is a trade name for London Premier Group
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Posted On: 2/27/2026, 9:36:13 PM
Last Update: 2/27/2026, 9:36:57 PM
The world's first 3D-printed monolithic catamaran that can sail in open waters was established by Caracol, an industrial 3D printer maker, and V2 Group, a large-format additive manufacturing supplier.
Using the Heron AM robot platform, a single print of the 6-metre-long catamaran was produced.
The design, weighing 1200 kg and measuring 5000 x 2300 x 1500 mm, required over 160 hours to print, resulting in a 20% reduction in lead time and a 30% decrease in waste creation during production.
The Heron 400 system utilised a High Flow Extruder with an 8 mm nozzle to produce components from a composite material of rPP + 30% GF, optimising for both structural performance and environmental sustainability.
Notably, rPP (Recycled Polypropylene) is a thermoplastic polymer derived from waste, reinforced with inorganic glass fibres to create a rigid, high-strength engineering material at a 30% concentration.
The company intends to scale and industrialise the boat's design, leveraging comprehensive research on design selection, material choice, and post-processing to comply with shipping industry standards and international regulations.
Moreover, large-format additive manufacturing robotic systems have revolutionised the shipping industry by providing highly customisable designs, optimising material usage to reduce waste compared to traditional shipbuilding, and lowering harmful emissions.
This project aims to establish a foundation for the future industrialisation of vessels by analysing each production stage to ensure efficient, sustainable, and economically viable scaling, thereby making the technology a broadly applicable solution for the maritime sector.
The first 3D printed catamaran for open waters exemplifies how additive manufacturing accelerates production, minimises raw material waste, and allows for the creation of customisable, robust maritime infrastructure for the global market.
Maritime Engineering Courses explore a 3D-printed monolithic catamaran that utilises naval architecture and marine-grade thermoplastic composites to form a single-piece hull. Key areas of study include load handling of the structure, material behaviour in marine conditions, and the adaptation of certification and production workflows to this construction method.
Produced in a single monolithic design through continuous additive manufacturing, the catamaran eliminates the need for large-scale assembly of critical components and enhances its structural integrity.
Before printing, the team carried out tests on complex sections of the boat with reinforcements and multiple layers to guarantee optimal performance and print quality.
Besides, the slicing and designing stages were time-consuming because of the boat's size, but they are one-time steps that can be reused for future prints of the same model, thereby decreasing preparation time for subsequent builds.
This shows that large-format additive manufacturing has significant potential for constructing maritime vessels, assuming further technological advancements.
This achievement marks a novel chapter in history in boat and nautical component manufacturing through robotic printing technology, minimising reliance on human labour.
Anticipated adaptations will enhance the production process for global navies, demonstrating the viability of robotic large-format additive manufacturing and ushering in a new era in boat and nautical component manufacturing.
Furthermore, conventional mass manufacturing of vessels typically relies on affordable methods like polyester and fibreglass lamination; however, there is a trend towards small batch, tailor-made production. Additive manufacturing eliminates the need for moulds, allowing for rapid design replications.
In short, companies are exploring the development of recyclable hulls to reduce carbon footprints and toxic waste, marking a significant advancement in the sector.
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