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UK Consortium Launches DEEP Project to Develop Intelligent Additively Manufactured Ship Propellers

September 25, 2025 Applications 114

A UK consortium is pioneering the use of 3D printing and digital twins to develop intelligent, self-monitoring ship propellers through the DEEP project.

Concept image of the Digitally Efficient Propeller (DEEP). Image from Enki Marine.

A UK-led consortium has launched the Digitally Efficient Propeller (DEEP) project, which aims to combine Additive Manufacturing (AM) with digital twin technology to create intelligent ship propellers capable of monitoring their own performance. Supported by funding from the UK's national innovation agency, Innovate UK, through the Clean Maritime Demonstration Competition (CMDC6), the project has received a grant to conduct a techno-economic feasibility study for the digital manufacturing of efficient propellers.

The DEEP project will explore the potential of various additive manufacturing methods within the complex and heavily regulated shipping industry. It will evaluate the performance of these methods compared to traditional techniques like casting and establish a structured process to secure class society approval and type certification. This ensures the project not only drives technological advancement but also provides a practical framework for industry application and regulatory compliance.

Consortium and Collaboration

The consortium, led by UK technology consultancy Enki Marine, brings together expertise from multiple organizations. Stone Marine Propulsion, a company specializing in marine propulsion systems, is responsible for design and market validation. TWI, an organization focused on engineering and materials technology, is handling materials testing and manufacturing. DEEPManufacturing, an additive manufacturing specialist, is managing the process and production scale-up. Authentise provides digital thread management and AI-driven monitoring. The Additive Manufacturing Center of Excellence at ASTM International oversees AM standards, certification, and best practices. Finally, Newcastle University contributes expertise in fluid dynamics modeling and validation.

"ENKI’s core mission is to ensure emerging technologies are not only cutting-edge but also safe, reliable, purposeful, and seamlessly integrated into the maritime landscape," said Milad Armin, Executive Director of Enki Marine. "We are incredibly privileged to be working with a world-leading consortium on the DEEP project, which will support our mission and pioneer the creation of a new generation of marine propellers manufactured using advanced Additive Manufacturing (AM) processes and enhanced with digital twin technology."

The DEEP project is scheduled to begin in September 2025, with an initial phase focusing on evaluating additive manufacturing processes. Later phases will involve testing a demonstrator on a research vessel at Newcastle University. The ultimate goals are to achieve type approval and scale up production for adoption by the global fleet. The project's significance lies in the potential for propellers made using 3D printing and digital twins to improve vessel efficiency and safety while reducing emissions. If successful, the project will validate new propeller designs and potentially establish the standards and approvals necessary for the broader shipping industry to adopt advanced manufacturing technologies at scale.

The consortium consists of Enki Marine, Stone Marine Propulsion, TWI, DEEP Manufacturing Ltd, Authentise, ASTM International, and Newcastle University. Image from Enki Marine.

Digital Twins and Additive Manufacturing

The combination of additive manufacturing with digital twin technology and AI-driven modeling has gained significant attention in recent months. It is being explored as a potential means to enhance performance, support certification processes, and strengthen operational monitoring across various industries.

For instance, Meta's Reality Labs Research released a digital twin catalog containing over 2,400 high-fidelity, millimeter-accurate 3D models of everyday objects. These digital twins help accelerate research into 3D object reconstruction for applications like immersive reality and e-commerce.

In China, a startup named Second Life raised $10 million to expand its AI algorithms and digital twin capabilities, enabling more robust 3D scanning, personalization, and the printing of avatars, thereby blurring the lines between physical forms, digital twins, and manufacturing.

Most recently, the UK government supported the STRATA project, led by Honeywell and partners including simulation software companies, metal additive manufacturing specialists, and academic organizations. This project aims to co-develop AI-powered aerospace components, where simulation and modeling work closely with additive manufacturing to meet the stringent safety, performance, and certification requirements of regulated industries.