Whilst mostly everyone will know something about propellers and that they drive a boat in the marine world, perhaps the one common thread of that knowledge will be that it is literally at the tail-end of the boat. Being the last component in the vessel drivetrain has meant that it is generally the most ignored in respect of the system. It is said that there is an art to designing the best & most efficient propeller but the essential character has not changed in decades if not centuries. Perhaps it is because it is at the end of the driveshaft and has a life insulated from the overall design of any vessel.
Most marine propellers comprise of a number of curved blades which are efficiently shaped radiating from a relatively narrow hub. Manufacture of these was always about a single cast component to ensure it was structurally robust for the application although in recent times, the advent of 4 and 5 axis CNC machining has enabled the exact & repeatable production of the complex 3D surfaces required. The core design for manufacture is unchanged. Some propellers are even subtractively machined from solid/cast blocks of the corrosion resistant metals necessary.
When one considers the repairability of such refined and clearly expensive parts, it is immediately understood that little can be done apart from replacement. Such work, due to the location underwater, requires almost always that the vessel be taken out of the water -- in effect dry-docked. It is also unlikely that the customised piece is in-stock (only for smaller craft) and so time & total cost of a new finished casting, with patterns et al, adds to the maintenance overhead. Even when a popular system has available parts, these are costed with high margins as there is no competitive market. Users are obliged for critical vessel operations to buy into a level of redundancy or pay for expensive short-delivery items.
Duodrive is seeking through this project to bring an advanced manufacturing technology to their innovative Contra-Rotating Electric Propulsion with systemic design to explore new opportunities and ideas from the perspective of the people who will be involved with or affected by them. A Marine Design specialist partner will ensure their propellers are more easily maintained & repaired. An on-demand manufacturing solution will be able to standardise parts availability at low cost whilst being able to include new features including biomimicry.