Kawasaki Heavy Industries installs WAAM 3D printed propeller blade | VoxelMatters - The heart of additive manufacturing

Wire Arc Additive Manufacturing (WAAM) is rapidly revolutionizing the marine industry, enabling the production of robust, high-performance parts in record time. Kawasaki Heavy Industries, Ltd., in collaboration with Pelagus 3D, recently demonstrated the transformative potential of WAAM technology by installing a Nickel Aluminium Bronze propeller blade on the BW Epic Kosan vessel, Epic Salina. This project showcases how additive manufacturing (AM) is reshaping the future of marine spare parts, delivering durable, on-demand solutions to meet the unique demands of maritime engineering.

Traditional methods for producing marine components, such as propeller blades, often involve casting, forging, or machining processes that are costly, time-consuming, and less environmentally friendly. AM introduces an innovative approach, creating complex components layer by layer, which can significantly reduce lead times, material waste, and operational costs.

Wire Arc Additive Manufacturing (WAAM) is a specialized AM technique that uses an electric arc as a heat source to melt metal wire. The melted wire is deposited layer by layer to create a near-net shape part. WAAM’s efficiency and scalability make it ideal for producing large metal components, such as propeller blades, that require high strength and durability.

Kawasaki Heavy Industries (KHI) has long been a leader in marine engineering, known for producing high-quality equipment and components for the global shipping industry. With a focus on innovative solutions and advanced technology, KHI’s foray into WAAM for manufacturing marine parts represents a logical evolution in its commitment to efficiency, durability, and sustainable engineering practices.

For the Epic Salina vessel, Kawasaki chose Nickel Aluminium Bronze as the material for the WAAM-produced propeller blade. This material is known for its corrosion resistance, strength, and durability in harsh marine environments, making it ideal for applications requiring high-performance components like propellers and thrusters.

One of the most notable advantages of the WAAM-manufactured propeller blade is the 40% increase in strength compared to traditionally manufactured parts. WAAM achieves this by producing components with near-full density, ensuring that the material properties are robust and reliable for demanding operational conditions.

The entire process, from design to installation, was completed in just six weeks. This quick turnaround is particularly beneficial for marine operators who often require timely repairs or replacements to minimize downtime. Traditional methods could take several months to produce and deliver a similar part, especially if the component needs to be custom-manufactured or shipped internationally.

Pelagus 3D, a joint venture between thyssenkrupp and Wilhelmsen, specializes in applying WAAM for large-scale industrial applications. For this project, Pelagus 3D played a crucial role in manufacturing the propeller blade, bringing expertise in WAAM to ensure that the component met Kawasaki’s strict performance and durability requirements.

The successful collaboration between Kawasaki, Pelagus 3D, and BW Epic Kosan underscores the value of combining expertise in marine engineering, additive manufacturing, and operations. This partnership allowed for a smooth and efficient production process, from design to installation, and demonstrated the potential of WAAM in creating high-quality marine components.