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Techno-Economy Feasibility Study of Manufacturing Digitally Enable Efficient Propellers (DEEP)

Projects/Open Innovation
10 hours ago
2 min read

The Digitally Enabled Efficient Propeller (DEEP) will investigate the potential impact and feasibility of producing smart, structurally optimised marine propellers via Additive Manufacturing (AM). With decarbonisation, operational efficiency, and digital integration as key drivers, DEEP aims to redefine the way propulsion systems are designed, manufactured, repaired, and operated across the maritime sector.




What makes DEEP innovative is not just the product---a next-generation propeller with internal cavities for weight reduction and embedded sensors---but the holistic, systems-level approach to sustainable shipbuilding. The project will evaluate three advanced AM technologies---Wire Arc Additive Manufacturing (WAAM), laser-based Directed Energy Deposition (DED), and Powder Bed Fusion (PBF)---and compare them against conventional casting to determine the most viable route for manufacturing large-scale, performance-critical components. This work is critical to overcoming a long-standing design plateau for more efficient designs caused by the limitations of traditional methods.


Led by ENKI, and delivered by a consortium of technical, manufacturing, and research partners including TWI, DEEP Manufacturing, Stone Marine Propulsion, Authentise, ASTM International, and Newcastle University, DEEP combines simulation, mechanical testing, lifecycle emissions analysis, and certification pathway planning to de-risk full-scale adoption.


A key outcome of this project is to establish the potential greenhouse gas (GHG) emissions savings due to lighter propeller weight, up to 15%, and utilising feedback from smart sensors to influence energy efficiency, fuel savings of 5-7%, during real-world vessel operation. These improvements could lead to lifecycle GHG emission reductions of 6,000 to 10,000 tonnes of CO₂e per vessel over 20 years. The potential for emissions savings through manufacturing and in-service use will be evaluated. DEEP will quantify cradle-to-grave material and energy consumption and assess the underwater noise-reducing benefits. The result will be a comprehensive techno-economic and environmental case for DEEP.


This 7-month feasibility phase is designed to deliver actionable evidence and a business case for a full-scale demonstration. Importantly, DEEP benefits from a credible demonstration pathway: Newcastle University has offered to use its research vessel, The Princess Royal, for future at-sea trials. With strong UK-based production and testing capabilities through DEEP Manufacturing and TWI, as well as end-user validation from Stone Marine Propulsion, the project is fully aligned with the goals of CMDC6 Strand 2\.


DEEP will position the UK as a leader in smart, clean, digitally enabled marine propulsion. It sets the stage for a new generation of vessels optimised for fuel efficiency, operational insight, and reduced emissions---delivering real-world impact through innovation and collaboration. 


👉 Find out what other projects we are working on here.


 
 
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