RESEARCH & DEVELOPMENT

LARGE FORMAT METAL AM & OTHER TECHNOLOGIES

Advanced Manufacturing

DEEP Advanced Manufacturing offers capability and expertise in large-format metal Additive Manufacturing, rapid prototyping, materials testing, and other areas.

DEEP has invested in technology within the Direct Energy Deposition (DED) family of Additive Manufacturing processes and is undergoing a technology development programme to advance this capability to the point of printing pressure hulls for the Sentinel Habitat.

DEEP is also developing capability in rapid prototyping including large-format polymer FDM 3D-printing, materials testing, generative design, and more.

close up of a RAMLAB robot working with sparks flying off metal
© 2023 RAMLAB
WAAM

Wire Arc Additive Manufacturing

Wire Arc Additive Manufacturing (WAAM) is a manufacturing method for 3D-printing large metal parts within the Direct Energy Deposition (DED) family of Additive Manufacturing technologies. Metal is deposited layer by layer by a welding robot which consists of a welding torch attached to a robotic arm, programmed to precisely lay down material according to a 3D CAD model. WAAM was selected by DEEP as the preferred manufacturing method for Sentinel pressure hulls due to its high deposition rates, scalability, and support for various metal feedstock materials.

DEEP has invested in a significant number of WAAM systems comprising Valk Welding torches, Panasonic robot arms, and RAMLAB control and monitor hardware and software. These can be used individually to produce parts across a wide range of materials and geometries. However, in order to produce the large segments comprising a Sentinel pressure hull, DEEP is undergoing an ambitious technology development programme with RAMLAB to develop multi-arm collaborative WAAM. This will see six individual WAAM systems arranged in a hexagonal configuration, working synchronously to produce 30T+ hull segments at world leading deposition rates.

In parallel, DEEP is working closely with DNV to achieve approval of the WAAM process for safety critical subsea applications. Collaboration with other industry leaders has accelerated creative problem-solving and breakthrough technological development, and DEEP is on track to deliver the first ever Additively Manufactured pressure vessel certified for human occupancy.

Laser Metal Deposition

Laser Metal Deposition (LMD) is another technology within the Direct Energy Deposition branch of Additive Manufacturing. Unlike WAAM, a laser is used to melt and deposit material. DEEP has invested in a Meltio Engine LMD system which is integrated on a robot arm and allows production of small to medium metal parts in a range of materials. Complex geometries are made possible by a 2-axis turntable and industry-leading path planning software from AI-Build.

DEEP is currently utilising its Meltio system for Advanced Manufacturing process development, rapid prototyping, and non-safety critical parts for the Sentinel and Subs products.

DEEP's spool of Wire

AM Feedstock Development

DEEP has collaborated closely with Valk Welding to select and optimise a Wire Arc Additive Manufacturing (WAAM) feedstock material for use in the Sentinel hull. This material has been carefully selected to ensure uniform weldability, material properties, and quality and is currently undergoing DNV Type Approval to affirm its suitability for subsea applications.

A bracket created by generative design

Generative Design

Generative Design is used at DEEP to access the full potential of Additive Manufacturing. This advanced design method uses AI algorithms to generate and assess optimised designs which would not be possible to create by traditional manual CAD processes. Generatively Designed parts often require less material to meet performance demands, resulting in quicker production and reduced waste.

benchtop plastometer device

Material Testing

Material testing plays a pivotal role in developing and certifying Advanced Manufacturing parts and processes. By evaluating mechanical properties, corrosion resistance, and fatigue performance, material testing forms the bedrock of effective engineering practices. Thorough material testing which mimics real world operating conditions informs material choices, design optimisation, and maintenance strategies, mitigating risks and enhancing reliability.

DEEP operates a Profilometry-based Indentation Plastometry (PIP) machine from Plastometrex. This cutting-edge equipment measures key material properties with very quick turnaround, enhancing our ability to optimise material choices and designs for various applications and supporting rapid material development.

Rapid Protoyping 3D Printing

Rapid prototyping offers DEEP and its partners a range of benefits, including accelerated time to market and cost reduction through early issue identification. It fosters innovation, facilitates effective communication, and promotes user-centric design by gathering early feedback. This approach mitigates risks, supports iterative improvement, and confers a competitive advantage, while fostering design flexibility and enhancing cross-functional collaboration.

DEEP operates three FDM 3D-printers: an Ultimaker S5, BCN3D Epsilon W27, and Builder Extreme Pro. These offer a comprehensive Rapid Prototyping capability and are containerised for easy transport and deployment anywhere in the world.

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DEEP Campus

Combining in-water infrastructure, on-water equipment and shore-side facilities DEEP Campus is the world’s most capable facility from which to design, manufacture, assemble, trial and test subsea equipment.

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Research Projects

Our Research team are inventing, re-inventing and refining the fundamental sciences that underpin today’s understanding of humankind’s ability to live and work subsea.