🔒UMaine to test 3D-printed boat in rigors of offshore conditions

The University of Maine’s Advanced Structures and Composites Center last week launched a 30-foot 3D-printed boat built to handle offshore conditions at speeds approaching 40 knots.

The boat was made on a massive 3D printer acquired by the center in 2019.

At the time, the technology, also known as additive manufacturing, was used to print a 25-foot, 5,000-pound boat. Christened 3Dirigo, the non-functional boat was printed over the course of three days to demonstrate the printer’s capabilities.

The latest product, 3Dirigo X, marked a major step in moving large-scale 3D printing from a technological demonstration toward a practical manufacturing tool, according to a news release.

3Dirigo X took four days to print. The longer print time was due to factors such as the boat’s design, built to withstand high seas and travel at 40 knots, as well as its larger size, thickness, durability and other considerations, a spokesperson told Mainebiz.

Open ocean

The launch and on-water demonstration took place in Hampden.

The vessel was engineered for higher speeds and the forces of offshore operation.

“We have developed technologies to design vessels that can withstand the kinds of extreme environments in the open ocean,” said Habib Dagher, the center’s founding executive director and a 2023 Mainebiz Business Leader of the Year honoree.

The vessel will be evaluated for its suitability in the Atlantic Ocean and its ability to withstand long-term stress.

“There is more work to do to continue to optimize the manufacturing process and the material properties,” he said.

Technology improvements

Since 2019, UMaine researchers have increased the print rate from about 20 pounds per hour when the research began to about 500 pounds per hour today.

Improvements in composite materials, digital design, sensors and process controls have helped shorten production timelines.

Because designs can be changed digitally, the same equipment can produce different hulls and components without requiring a new mold for each one.

Moving from prototype to widespread use will require the technology to be repeatable, inspectable and affordable. The goal is not to replace traditional shipyards or skilled workers, but to provide another tool that could reduce reliance on specialized molds, speed design changes and expand production capacity.

The technology could have applications in commercial boatbuilding, unmanned vessels, patrol craft, logistics vessels, sensor platforms, replacement components and other specialized systems. Digital designs can be modified for different missions or operating environments without the need to first build new molds and tooling.

The project gives UMaine students hands-on experience with advanced manufacturing technologies, digital design, materials science and AI while working alongside researchers. The center has employed more than 3,000 student interns over the years.

Related projects

In 2022, the center produced a house prototype made from four 3D-printed modules designed to meet all building code requirements and tested in subsequent weather conditions. The center is now working with Bangor nonprofit Penquis and MaineHousing to create a 3D-printed neighborhood in Greater Bangor.

UMaine is also preparing to open its 55,000-square-foot GEM building (formerly called the Green Engineering and Materials Building).The building will include AI-enabled 3D printers and advanced computational tools.

“The Factory of the Future will allow us to significantly expand our capabilities and reach a deposition rate of 1,000 pounds an hour,” said Dagher.