DEEP Manufacturing Ltd has completed the printing of a section of a next-generation, digitally enabled marine propeller blade, marking a major milestone in the Digitally Enabled Efficient Propeller (D.E.E.P) project.

The seven-month program is demonstrating how industrial-scale additive manufacturing can unlock lighter, smarter, and more efficient propulsion systems for the future of clean shipping. The propeller is made from Nickel Aluminum Bronze (NAB) using the process of wire arc additive manufacturing (WAAM). Timelapse footage has captured the blade taking shape—offering a rare insight into the additive manufacture of large-scale marine propulsion components.

Traditional propellers are typically produced using casting processes, which can restrict design flexibility and limit performance optimization. D.E.E.P is investigating how industrial 3D printing can overcome these constraints, enabling lighter, more efficient, and more intelligent propulsion systems designed for the future of clean and smart shipping.

At the center of the project is a structurally and hydrodynamically optimized blade architecture. This approach offers lighter, more efficient blades while allowing real-time data collection. In time, this could allow vessels to monitor propulsion performance in real time, autonomously optimize engine power and speed, and enable predictive maintenance.

Led by Enki Marine Ltd—responsible for system integration and commercialization—the consortium includes DEEP Manufacturing Ltd, Stone Marine Propulsion, TWI, Authentise, ASTM International, and Newcastle University—spanning expertise in design, materials testing, digital workflows, certification, and hydrodynamic validation.

WAAM offers potential lead time reductions of up to two thirds compared to conventional casting, while supporting regional production and improved supply chain resilience. This milestone comes as DEEP Manufacturing continues to scale its WAAM capability internationally, including recent expansion into Houston, where increasing demand for large-scale, high-integrity metal components is accelerating adoption across energy, defence, and maritime sectors.

Peter Richards, CEO, DEEP Manufacturing Ltd—which is overseeing the manufacturing processes and production scaling—said, “This is the point where digital ambition becomes physical reality. We are not simply printing a propeller; we are demonstrating a new way of thinking about propulsion design, production, and long-term resilience.”

He continued, “As we continue to scale our WAAM capabilities internationally, including our recent expansion into Houston, we are seeing first-hand how demand is growing for faster, more flexible manufacturing of large-scale, high-integrity components across critical industries.”

The next phase of the program will focus on scaling to a full-size propeller sea trial and operation optimization platform development.

For more information: www.deep.com