Executive Summary
International Submarine Engineering (ISE) successfully replaced traditionally machined parts on their Explorer-Class AUVs with 3D printed components from Forge Labs, achieving remarkable cost reductions of up to 73% and lead time improvements from 3-4 weeks to just 2-3 days. This case study demonstrates the transformative potential of additive manufacturing in the demanding marine technology sector.
International Submarine Engineering has been a world leader in the design and integration of autonomous and remotely operated robotic vehicles since 1974. Their Autonomous Underwater Vehicles (AUVs) are sophisticated unmanned submarines used to survey ocean floors, studying everything from underwater volcanoes and oil deposits to continental shelf formations. The transition to 3D printing technology has enabled ISE to overcome traditional manufacturing constraints while maintaining the stringent quality standards required for subsea operations.
Manufacturing Challenges in Marine Technology
Traditional Manufacturing Constraints
- •Complex CNC machining requiring specialized tooling and multiple setups
- •Hand-fabricated parts with inconsistent quality and high labor costs
- •Extended lead times of 3-4 weeks for complex geometries
- •Limited design freedom for compound-curve surfaces
Marine Environment Requirements
- •UV stability for extended surface operations
- •Neutral buoyancy characteristics for optimal AUV performance
- •Hydrodynamic efficiency to minimize drag
- •Corrosion resistance in saltwater environments
"Making short run production parts can be very expensive when using complex CNC machining and fabrication - 3D printing has allowed us to produce complex parts and one-offs much more cheaply than traditional methods."
FDM Technology Selection for Marine Applications
Fused Deposition Modeling (FDM) was strategically selected as the optimal 3D printing technology for ISE's end-use AUV components. This decision was based on several critical factors that align perfectly with marine manufacturing requirements and operational constraints.
FDM Advantages for Marine Components
Technical Benefits
- • Large build volumes accommodate substantial AUV components
- • Production-grade thermoplastics with marine-certified properties
- • Excellent mechanical strength for structural applications
- • Superior chemical resistance to marine environments
Economic Benefits
- • Competitive pricing for prototype and production volumes
- • Rapid turnaround times enabling faster development cycles
- • No tooling costs for complex geometries
- • Material efficiency with minimal waste generation
ASA Material Properties for Marine Applications
Acrylonitrile Styrene Acrylate (ASA) was selected as the primary material for ISE's marine components due to its exceptional performance characteristics in demanding marine environments.
Component Case Studies
Case Study 1: LED Panel Mounting System
Challenge
The LED panel installation on the AUV's curved hull presented a unique engineering challenge. The bracket required complex geometry to accommodate the panel's irregular positioning within the curved submarine body, necessitating a drilling template for precise hole placement.
Traditional Approach
- • Complex multi-axis CNC machining operations
- • Separate drilling template fabrication
- • Limited design optimization for hydrodynamics
- • High setup costs for custom geometry
3D Printing Solution
Design Optimization
- • Perfect fit to submarine's compound-curve surface
- • Integrated drilling template functionality
- • Hydrodynamically optimized external surfaces
- • Single-piece construction eliminating assembly
Performance Benefits
- • Self-locating installation reduces assembly time
- • Improved flow characteristics reduce drag
- • ASA material provides UV stability for surface operations
- • Neutral buoyancy maintains AUV balance
Case Study 2: Obstacle Avoidance System
Engineering Challenge
The AUV's obstacle avoidance system required a sophisticated mounting bracket that perfectly matched the compound-curve surface of the submarine hull. Traditional manufacturing demanded hand-fabricated parts, resulting in inconsistent quality and field replacement difficulties.
Cost Analysis
Case Study 3: Plane Extensions (Fins)
Traditional Fiberglass Process
The Explorer-Class AUV's plane extensions were traditionally manufactured using fiberglass, involving a complex multi-step process with multiple molded pieces requiring adhesive bonding and subsequent machining operations.
Process Complexity
- • Multiple mold fabrication and setup
- • Hand layup with resin infusion
- • Curing and demolding operations
- • Assembly with structural adhesives
- • Secondary machining for final dimensions
- • Surface preparation and finishing
3D Printing Transformation
Manufacturing Simplification
- • Single-piece construction eliminates assembly
- • No tooling or mold requirements
- • Direct from CAD to finished part
- • Integrated mounting features
Performance Improvements
- • Reduced weight compared to fiberglass
- • Superior surface finish compatibility
- • Enhanced dimensional accuracy
- • Improved hydrodynamic efficiency
Quantified Benefits
Technical Implementation Strategy
Design for Additive Manufacturing (DfAM)
- •Topology optimization for weight reduction while maintaining structural integrity
- •Integration of mounting features and fastener points
- •Hydrodynamic surface optimization using computational fluid dynamics
- •Material orientation for optimal strength-to-weight ratios
Quality Assurance Protocol
- •Dimensional verification using coordinate measuring machines
- •Material property validation through mechanical testing
- •Surface finish inspection and post-processing requirements
- •Fit and function verification in operational environments
Post-Processing and Finishing
To achieve seamless integration with the AUV's fiberglass hull, the 3D printed fins underwent specialized post-processing to match the existing surface finish characteristics.
Surface Preparation
Progressive sanding and smoothing to remove layer lines
Primer Application
Marine-grade primer for enhanced adhesion and durability
Final Coating
Color-matched paint system for visual integration
Industry Impact and Applications
ISE's successful implementation of 3D printing technology demonstrates the transformative potential of additive manufacturing in the marine technology sector. This case study has implications across multiple related industries and applications.
Applicable Industries
Aerospace
Lightweight components for UAVs and satellite systems
Automotive
Prototype and low-volume production components
Robotics
Custom housings and mechanical assemblies
Key Success Factors
- •Early engagement with additive manufacturing specialists
- •Comprehensive material property validation
- •Design optimization for additive manufacturing processes
- •Thorough testing in operational environments
- •Established quality assurance protocols
Future Opportunities and Expansion
Next-Generation Applications
Building on the success of these initial implementations, ISE is exploring advanced applications of 3D printing technology for more complex subsea systems and components.
Sensor Integration
Embedded electronics and sensor housings with integrated cable management
Propulsion Components
Optimized impellers and flow management systems for enhanced efficiency
Pressure Vessels
Lightweight housings for deep-sea applications with enhanced pressure resistance
Technology Roadmap
The success of this initial implementation has established a clear roadmap for expanding 3D printing applications throughout ISE's product portfolio.
Short-term Goals
- • Expand component catalog to include additional structural elements
- • Implement multi-material printing for enhanced functionality
- • Develop in-house printing capabilities for rapid prototyping
Long-term Vision
- • Integration of metal 3D printing for critical components
- • Development of custom materials for marine environments
- • Complete AUV systems manufactured using additive processes
Conclusion and Key Takeaways
International Submarine Engineering's successful implementation of 3D printing technology for AUV components demonstrates the transformative potential of additive manufacturing in demanding marine applications. The project achieved remarkable cost reductions, dramatic lead time improvements, and enhanced design capabilities while maintaining the stringent quality standards required for subsea operations.
Strategic Recommendations
- •Engage with additive manufacturing specialists early in the design process to maximize benefits
- •Invest in comprehensive material property validation for mission-critical applications
- •Develop design for additive manufacturing (DfAM) capabilities within engineering teams
- •Establish clear quality assurance protocols and testing procedures for additive components