The Digitally Enabled Efficient Propeller (DEEP) project is a 7-month feasibility study exploring how Additive Manufacturing (AM), also known as industrial 3D printing, can create the next generation of marine propellers. Traditional propellers are typically made using casting processes, which can limit design flexibility and performance. DEEP aims to overcome these limitations by leveraging AM technologies to manufacture smarter, lighter, and more efficient propellers that are fit for the future of clean and smart shipping.
At the core of DEEP's innovation is a new propeller design that includes internal cavities to reduce weight and provide space for future embedded sensors. These features could one day allow vessels to monitor their own propulsion systems in real-time, improving operational efficiency by autonomously adjusting the engine's power and speed, and enabling predictive maintenance. The project is focused on comparing three advanced AM processes---WAAM, laser-based Directed Energy Deposition (DED), and Powder Bed Fusion (PBF)---to understand which is best suited to producing large, high-performance marine components.
Throughout the project, the DEEP team will use simulation, mechanical testing, and lifecycle analysis to evaluate the environmental and economic benefits of AM-based propellers. This includes analysing potential greenhouse gas (GHG) emissions savings from both the manufacturing process and reduced fuel consumption, thanks to improved operational efficiency. The project will also assess the potential for reducing underwater noise pollution due to improved vibration control and structural properties.
The DEEP project is led by ENKI and delivered in collaboration with expert partners from across the UK, including TWI, Stone Marine Propulsion, DEEP Manufacturing, Authentise, ASTM, and Newcastle University. Each organisation brings unique expertise in testing, manufacturing, digital workflows, certification, or hydrodynamic performance.
One of the most exciting aspects of DEEP is its future potential: Newcastle University has offered its research vessel, The Princess Royal, as a platform for real-world testing in a future demonstration phase. This ensures that what is developed during this study can move quickly toward practical application.
By exploring more innovative ways to build and operate propellers, DEEP supports the UK's goal of becoming a global leader in clean maritime technology. It helps pave the way for more sustainable, intelligent vessels and a stronger, more innovative shipbuilding supply chain.