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17/03/25
Ferretti Group, a global leader in luxury yacht design and manufacturing, has embraced large-format additive manufacturing (LFAM) from Caracol to produce key superstructures for its latest model, the Pershing GTX116.
In collaboration with Caracol, Ferretti Group implemented the Heron AM system to 3D print the yacht’s air grilles and windshield visor, marking a significant innovation in yacht construction. This advanced robotic LFAM technology allows for lighter, stronger, and more aerodynamically efficient components while significantly reducing production time and material waste.
Traditionally, yacht components such as air grilles and superstructures were manufactured using manual fiberglass lamination on molds. This process is highly labor-intensive, requiring skilled workers to create multiple molds, particularly for complex geometries. As a result, the traditional method leads to increased production costs, extended lead times, significant material waste, and limited opportunities for customization.
With Heron AM technology, yacht manufacturers can eliminate the need for mold-based processes and directly print composite parts from digital designs. This shift in production methodology reduces material and labor costs while enabling rapid iteration and prototyping. Complex geometries that were once difficult to achieve are now seamlessly fabricated using LFAM, allowing for aerodynamic and aesthetically refined designs. Additionally, this innovative approach significantly enhances sustainability by minimizing material waste and improving overall energy efficiency.
The Pershing GTX116 is a 35-meter sports yacht that blends elegance, comfort, and high-speed capabilities. Designed to deliver a luxurious and dynamic seagoing experience, the yacht benefits from LFAM technology to optimize aerodynamics and weight distribution. The 3D printed air intake grilles and visor, produced using Caracol’s Heron AM system, enhance performance and durability. The integration of this technology results in a yacht that is not only visually striking but also more efficient in terms of fuel consumption and weather resistance.
The Pershing GTX116’s aerodynamic grilles were produced using the Heron 300 system, featuring a high-accuracy extruder with a 3 mm nozzle size. The material used for printing was ASA reinforced with 20% glass fiber, providing strength and durability. The printing process took 72 hours, resulting in a final component weighing 40 kg and measuring 4200 x 400 x 400 mm. To ensure optimal aesthetics and weather resistance, the grilles underwent a finishing process involving the application of a gel coat.
Adopting large-format additive manufacturing for these yacht components brought significant advantages compared to traditional manufacturing methods. The production lead time was reduced by 50%, allowing faster delivery without compromising quality. Additionally, material waste was cut by 60%, making the process more environmentally sustainable. The final components were also 15% lighter, contributing to better yacht performance.
As we’ve been arguing for nearly a decade, integrating large format additive manufacturing in yacht construction has a huge potential for marine industry applications. The success of Caracol’s Heron AM technology in the Pershing GTX116 project highlights its potential for producing customized, high-performance yacht components. In the future, additive manufacturing is expected to play a crucial role in the development of advanced hull structures, interior superstructures, and even fully 3D printed yacht prototypes.
Copyright : VoxelMatters
