Print Email Facebook Twitter On the Assessment of Additive Manufacturing Potential in the Maritime Construction Sector Title On the Assessment of Additive Manufacturing Potential in the Maritime Construction Sector: The Effect on Ship Design Author van der Zalm, M. Contributor Hekkenberg, R.G. (mentor) Hopman, J.J. (mentor) Custers, K. (mentor) Faculty Mechanical, Maritime and Materials Engineering Department Marine and Transport Technology Programme Marine Technology - Ship Design Production and Operation Track – Ship Design Specialisation Project SDPO.16.023.m Date 2016-11-08 Abstract Additive manufacturing, colloquially known as 3D printing, is a production process that offers possibilities compared to conventional production methods. Current methods involve shaping or removing of material to create parts, where additive manufacturing adds material. Several industries have successfully implemented the technology showing improvements for components such as 50% weight reduction or better performance. These opportunities do not seem as relevant in the maritime construction sector, therefore determining the potential requires more detail. The goal of this report therefore is set as: Asses the potential for additive manufacturing in the maritime construction sector and show its effect on ships through case studies. This goal is realized by providing an overview of additive manufacturing capabilities, opportunities and challenges related to maritime technology. It is found that the most interesting opportunities are: • Weight reduction • Performance improvement • Part consolidation and integrated functionality • Customization To further analyse the potential, the effect on system engineering, ship design and mechanical engineering is considered. It is assumed that the effect is mostly on mechanical engineering level, where the added value shows through the effect additive manufacturing has on the shape and function a part fulfils. Cost and fitness models are created to be able to quantify the added value additive manufacturing has. These are applied to the components gathered from vessel data and brainstorm sessions with the project partners. After this filtering, optimization is considered for all of the selected components, based on the opportunities of additive manufacturing. To determine the possible weight reduction a case study is performed using topology optimization on a rudder. This confirmed that a weight reduction from literature of 25% and for a rudder further reduction up to 40% is possible. From selected components it is found through detailed analysis that fairleads are 10 times more expensive to print compared to the current pipe-based design. Ladders, air gratings are examples where the costs are similar to the current design, so a more detailed analysis is necessary for a verdict on these components. The mast of an lightweight offshore vessel produced with additive manufacturing can be cheaper, lighter and faster in production than the current composite design also offering the option of optimizing for a certain eigenfrequency to improve radar movement. Finally, rudders can be produced at similar costs as the current design but when printed, have the opportunity to be printed in a custom shape. This means features such as a twisted rudder can be implemented without additional costs. A case study is also performed for printing the entire hull of vessels, with an assumed weight reduction. This weight reduction then leads to fuel reduction from which return of investment is calculated. It is found that printing hulls is not feasible, since the average return of investment time is 282 years. The costs of additive manufacturing have to be 4 times lower or the weight savings have to be 75% to reach payback times of 5 years for some vessels. The implications of this thesis are that a general model is available for analysing components for additive manufacturing. This means that if the market changes or other components are requested to be printed, an analysis can easily be made. This thesis is part of a project called a GRaduation Industry Project (GRIP) in collaboration with Damen, Feadship and TNO and two other graduate students, Jurrit Bersgma and Martijn Obers . The two other students focus on the topics of production and structures, providing a total overview of the potential of additive manufacturing in the maritime construction sector. Subject Topology Optimization3D printingAdditive ManufacturingShip Design To reference this document use: http://resolver.tudelft.nl/uuid:c16662b2-0925-449f-8368-da8ad156eb26 Embargo date 2021-11-08 Part of collection Student theses Document type master thesis Rights (c) 2016 van der Zalm, M. Files PDF report.pdf 9.57 MB Close viewer /islandora/object/uuid:c16662b2-0925-449f-8368-da8ad156eb26/datastream/OBJ/view