3D-Printed Boats Are Finally Getting Real

/ Technology / By

A boat hull is the kind of object 3D printing has always promised to make cheaper: big, complex, labour-heavy, and usually slow to build. In the Dutch city of Delft, one team says it can now print a hull in days rather than weeks by combining a tailored plastic‑and‑fibreglass mix with a large-format printer that can lay down material almost continuously.

If the approach holds up in the real world, it’s not just a novelty “printed boat” story. It’s a test of whether additive manufacturing can move beyond small parts and prototypes into regulated, safety-critical products—while changing where and how manufacturing happens.

Why boatbuilding is such a tempting target for automation

Boatbuilding is famously labour intensive because the environment is unforgiving. Salt water, sunlight, repeated impacts, and biological growth (fouling) punish materials and manufacturing shortcuts. Traditional fibreglass construction also tends to rely on moulds and careful manual work to ensure the hull is strong in the right places.

That combination—high labour, long lead times, and a lot of repetitive work—creates a straightforward incentive: if you can shift more effort into design and less into hands-on fabrication, you can potentially cut time and cost.

That’s the logic behind CEAD’s bet. In Delft, Maarten Logtenberg (a co-founder of CEAD) describes their goal as automating “almost 90% of the boat-building process.” Once the design is finalised and the printer is set up, the production phase can, in theory, run with little human intervention beyond feeding the base material and monitoring the process.

The material problem: strength, sunlight, and sea growth

The hard part isn’t the printer—it’s the hull material.

To build a hull that can be used (not just displayed), the printed structure needs to survive impacts and resist long-term degradation. In Delft, a simple “sledgehammer test” became a milestone: Logtenberg describes a sample that a sledgehammer “simply bounced off,” barely leaving a scratch.

That test wasn’t about showmanship; it was a proxy for an engineering question. A hull needs toughness and stiffness, but also resistance to UV exposure and the tendency for marine growth to stick to surfaces.

CEAD’s answer was a particular mix of thermoplastics and fibreglass. The BBC reports the resulting material is strong, does not need an extra coating to protect it from sunlight, and is resistant to fouling and marine growth.

Those properties matter because they remove steps. If a printed hull requires a lot of post-processing—extra coatings, extensive finishing, or structural reinforcement—the “print it fast” advantage can collapse into a different kind of labour bill.

How large-format 3D printing changes the manufacturing workflow

A useful way to think about additive manufacturing is that it front-loads complexity.

In traditional fibreglass building, a mould and manual layup processes do much of the work. In large-format 3D printing, the work shifts earlier:

  • The design must be specified precisely enough that the machine can build it layer by layer.
  • The printer has to be engineered to handle large, continuous builds.
  • The material formulation and deposition process have to produce reliable bonds between layers.

CEAD’s printers build the boat “one layer at a time” to a digital design, with each layer bonding to the last to create a single, seamless object.

A key benefit of that approach is iteration. If you want to change a design, you can often update the digital model and the print plan rather than retooling a mould. That matters in markets where requirements are uncertain, or where customers want customisation.

CEAD’s largest 3D printer is nearly 40m (131ft) long, according to the BBC, and has already been used by a customer in Abu Dhabi to print an electric ferry. That size is the difference between printing small components and printing entire hull sections.

Early use cases: military prototypes and unmanned vessels

The most plausible early markets are the ones that value speed, iteration, and flexibility more than they value tradition.

The BBC says that in the 12 months since CEAD began operating its Marine Application Centre in Delft, the team has built a prototype 12m fast boat—similar to a rigid inflatable boat (RIB)—for the Dutch Navy.

Logtenberg contrasts that with the usual procurement story: “Normally when the Navy buys a boat, it takes them years before they receive it and they pay quite some money.” In this case, he says the team did it in six weeks, on a “very limited budget.”

There’s another angle that fits additive manufacturing’s strengths: unmanned vessels. The BBC notes a test with Nato Special Forces in which “nautical drones” were built on site in a matter of hours, with designs changing according to operational requirements.

Two ideas show up repeatedly in these examples:

  1. Relocating production. Even a substantial printer can be carried in a shipping container and moved closer to the end user.
  2. Transporting feedstock instead of finished products. Logtenberg argues that rather than shipping a bulky hull, you ship base material in large bags, which can be more transport efficient.

Those advantages are most compelling in contexts where logistics and time matter as much as unit cost.

The consumer story: novelty now, cost later

In Rotterdam, another company is trying to make printed boats work in the leisure market.

Raw Idea’s “Tanaruz” brand, the BBC reports, is looking particularly at rentals. Joyce Pont, Raw Idea’s managing director, says consumers can be hesitant because the product is novel, but the rental market is keen. Part of the appeal is marketing: “we’ve got a 3D printed boat,” and people want to see and touch it.

Raw Idea also highlights materials. The BBC says it uses a mix of glass fibre and recycled consumer plastics (such as fizzy drinks bottles) in hulls.

For now, that doesn’t automatically mean lower prices. Pont says the price is currently comparable to a traditionally built boat because recycled material costs more to buy. But she expects scale and flexibility to bring costs down.

She also makes a bold prediction: within five years, she believes 3D printed boats could take over the fast-driving workboat/speedboat segment.

Predictions like that are easy to dismiss—until a few operational realities move.

The constraint that decides everything: regulation and certification

Boats aren’t smartphone cases. The marine industry is heavily regulated, and certification tends to be conservative for good reason.

The BBC reports that both CEAD and Raw Idea are engaging with European regulators “almost in real time” as they use new materials and new methods to build vessels that cannot be easily compared to older manufacturing approaches.

That’s a fundamental issue for additive manufacturing: even if the physics works, the “paperwork layer” has to catch up. Regulators need to understand:

  • What the material is, how it degrades over time, and how it behaves under stress
  • Whether the layer-by-layer build introduces new failure modes
  • How to standardise testing and inspection for printed structures

In practice, certification can be the rate limiter. If regulators can’t sign off quickly, the fastest printer in the world doesn’t help.

So will we ever print an entire ship?

The BBC is clear that we’re a long way from printing whole ships in one go.

Pont is sceptical that full-scale ship printing is imminent, arguing that superyachts and similar vessels are a “craft” that will resist automation.

Logtenberg is more optimistic. He says that even building a 12m boat was beyond what he expected a year earlier. He frames the long horizon like this: shipbuilding already happens in modules, and it could take “a decade or two” to completely print a ship’s hull, but continued research into thermoplastics and scaling up machines could make it feasible.

The way to read that isn’t as a guarantee—it’s as a roadmap. The barrier is not just bigger printers. It’s long-term materials research, process reliability, and the confidence of regulators and customers.

Bottom line

Large-format 3D printing for boats is finally starting to look like more than a gimmick because teams are solving the unglamorous part: materials that can survive sunlight, impact, and the marine environment. If certification frameworks keep pace—and if early markets like military prototypes, unmanned vessels, and rentals keep buying—printed hulls could become a real manufacturing category rather than a curiosity.

Sources

n English