Today's KNOWLEDGE Share
“Robotic 3D printing can compete with traditional boatbuilding”, Simone Barbera and Mattia De Santis, Caracol
V2 catamaran was printed in Italy at Caracol’s production center and headquarter in Barlassina, near Milan, with a Heron AM 400, Caracol’s robotic Large Format Additive Manufacturing (LFAM) platform. The lattest was specifically configured with a 7-axis robotic arm mounted on a rail, enabling the printing of parts up to 10 meters in length.
How did the collaboration between V2 Group and Caracol come about?
Simone Barbera: The collaboration between V2 Group and Caracol originated from a shared vision to revolutionize boat manufacturing through sustainable innovation. V2 Group, a Spanish-company specialized in nautical design and engineering, is seeking to develop electric vessels manufactured sustainably. On the other hand, Caracol, leader in robotic advanced manufacturing technology, had had years of experience working with Large Format Additive Manufacturing for the marine sector. Together the two companies could collaborate to transform their concept to life. This partnership naturally aligned around each other’s complementary strengths: V2’s expertise in marine design and Caracol’s pioneering robotic manufacturing technology. Together, we set out to develop a scalable, industrialized approach to boat production, focusing emphasized sustainability, efficiency, and customization.
What types of work do the two companies usually produce?
Simone Barbera: V2 Group is dedicated to manufacturing components and boats using 3D printing technologies. Born as a startup, it is currently in the midst of a funding round to raise capital that will enable it to scale its business to the next level. Caracol specializes in robotic advanced manufacturing technology, particularly with its large format additive manufacturing platforms – Heron AM for composite pellet extrusion and Vipra AM for metal wire deposition. These platforms’ applications span multiple sectors beyond marine, such aerospace, automotive, railways, as well as construction or architecture. Notably, in the marine field, Caracol previously collaborated on finished parts for luxury yacht builder such as Ferretti Group or San Giorgio Marine, and developed Beluga, the world’s first monolithic 3D-printed sailboat.
How did the idea for this project come about? Was it an order?
Simone Barbera: The concept was to design a ultra-comfortable, American- style pontoon boat, starting from a first digital prototype and culminating with the production of a functional boat, suitable for open waters, entirely fabricated leveraging additive manufacturing in an uninterrupted 160 hours print cycle. The project served both as a proof-of-concept for scalable production and as a demonstration that robotic 3D printing can compete with traditional boatbuilding in cost, efficiency, and sustainability.
How was the work divided between the two companies?
Simone Barbera: V2 Group led the initial stages of the project, overseeing concept development, naval architecture, and the overall design definition. For the first prototype, they also provided the structural loading scenarios that served as the basis for further engineering work. Caracol then took over the engineering of the design for large-scale additive manufacturing. This included adapting the geometry to suit 3D printing constraints, modifying the design to integrate structural and functional features, and performing structural and finite element (FE) analyses to validate its mechanical integrity. In parallel, Caracol developed dedicated features within its proprietary slicing software to enable efficient path planning and process optimization. Digital simulations and printing tests were carried out to refine the parameters before moving on to the final production. Caracol also managed the complete printing process and post-processing of the part.
This is a ‘robotised’ 3D printing technology. What automation is used on the device?
Mattia De Santis: The Heron AM system utilizes a highly automated architecture to enable large-scale robotic 3D printing. At its core, the system features an industrial 7-axis robotic arm—typically from Kuka, though it is compatible with other anthropomorphic robotic arms—mounted on a motorized rail to extend its working area. What transforms this robotic setup into a functional 3D printer is Caracol’s proprietary automation technology, which includes a custom-developed extrusion system, motion control algorithms, and robotic coordination software. This automation stack manages key stages of the additive manufacturing process, including motion sequencing, extrusion synchronization, and deposition path execution—turning a general-purpose robotic arm into a fully operational 3D printing system.
For this specific project, additional automation features were developed to handle the unique geometry and scale of the vessel. These include optimized path planning routines and dynamically adjustable printing parameters, allowing the system to maintain accuracy, stability, and structural consistency throughout the build. This high level of automation ensures that the entire deposition process is repeatable, efficient, and suitable for manufacturing large, complex parts with minimal human intervention.
What materials are used?
Mattia De Santis: The material used for this project was recycled polypropylene reinforced with glass fiber (rPP+GF). It was selected for its optimal balance between mechanical performance, cost-efficiency, and durability in marine environments. From a sustainability standpoint, the material offers clear advantages: being recycled, it reduces the environmental impact typically associated with virgin plastic production, and it is itself recyclable at end-of-life. This aligns with the project’s broader goals of minimizing waste and promoting circularity in boatbuilding through additive manufacturing.
The aim of this boat is to enable industrialisation. From design to materials, production and post-processing, what innovations have been put in place to achieve this?
Mattia De Santis: To enable industrialization of the AM Catamaran, several targeted innovations were implemented across all stages of the project:
Design: The vessel was developed using a Design for Additive Manufacturing (DfAM) approach, aimed at reducing the number of components and enabling monolithic construction. The hull and internal structures were printed in a single piece (99% of the boat), eliminating the need for molds or assembly-intensive processes.
· Materials: The use of recycled polypropylene reinforced with glass fiber (rPP+GF) was a strategic choice. This material provided a good balance between mechanical performance and cost-efficiency while supporting sustainability goals. Its recyclability and availability at industrial scale make it suitable for repeated production.
· Production Process: Caracol leveraged its Heron AM platform, integrating a robotic arm on rails and a high-throughput extrusion system tailored for large-format printing. For this project, custom automation features were developed to handle the boat’s complex geometries and scale—optimizing path planning and printing parameters to ensure repeatability and structural consistency.
Post-Processing: A qualification process for the material was carried out to ensure compatibility with marine post-processing techniques such as gel coating. This ensures that printed parts meet aesthetic and protective requirements, similar to conventional boatbuilding standards.
· Workflow Simplification: By eliminating traditional prototyping, mold fabrication, and manual layup stages, the team accelerated the production timeline significantly. The boat was fully printed in just 160 hours, demonstrating a viable path for scaling production with minimal labor and reduced lead times.
These combined innovations aim not only to validate the feasibility of additive manufacturing for real-world marine applications but to establish a repeatable, scalable workflow suitable for small-series or customized production runs.
Are other partners involved in certain stages?
Simone Barbera: After the 3D printing process was completed at Caracol’s facility, the hull was sent to a third-party specialist for CNC machining to refine critical surfaces and ensure dimensional accuracy. The gel coating was applied by an external partner with expertise in marine-grade finishes, while Caracol handled the final painting in-house to guarantee aesthetic consistency and quality control. Once post-processing was complete, the finished hull was delivered to V2 Group who managed the systems installation and final outfitting of the vessel, including integration of the propulsion unit, battery systems and electrical components. This collaborative workflow was essential to ensuring each phase met the standards required for an industrialised, functional marine product.
In what ways does 3D printing offer a significant reduction in environmental impact in this context?
Mattia De Santis: 3D printing dramatically reduces environmental impact in boat manufacturing through multiple channels. The additive process minimizes material waste by using only what’s needed, unlike subtractive methods. We can utilize recycled polypropylene reinforced with glass fiber (rPP+GF) instead of virgin composites. The technology eliminates the need for traditional molds and toxic lamination processes typical in boatbuilding. Component consolidation reduces assembly requirements and associated emissions; Digital manufacturing shortens production cycles by approximately 70%, saving energy and resources. Finally, the resulting vessels are lighter, requiring less energy during operation. Together, these factors create a significantly more sustainable manufacturing ecosystem.
Have you already received orders for this type of project?
Simone Barbera: Following the successful demonstration of this prototype, we’ve received significant interest from marine industry partners looking to develop similar sustainable vessel solutions. Potentially also by combining Additive Manufacturing with traditional approaches. While specific details on these projects remain confidential as still in preliminary stages, the market response confirms our belief that this technology represents the future of boat manufacturing. We’re currently working on a new V2 catamaran while other customization projects are currently in the planning phase, leveraging the lessons learned from this pioneering prototype to create bespoke vessels with similar environmental benefits and production efficiencies.
Has the robotised technology been applied to other markets (automotive, aerospace, etc.)?
Simone Barbera and Mattia De Santis: Yes, Caracol’s robotic additive manufacturing technology has been successfully applied across various industries beyond marine applications, including aerospace, automotive, railways, and design.
In the aerospace sector, Caracol collaborated with D-Orbit and the Politecnico di Milano to produce a pressurized aluminum tank using Wire Arc Additive Manufacturing (WAAM). This tank is intended for CubeSat carrier space vehicles, demonstrating the capability of Caracol’s technology to create complex, high-performance components for demanding space applications. In the automotive industry, Caracol has contributed to several innovative projects. In collaboration with Duqueine, it developed large-scale 3D-printed direct molds for composite parts used in racing car manufacturing, drastically reducing lead times and tooling costs while maintaining precision and surface quality. Additionally, in partnership with Van Venrooy, Caracol produced end-use components for custom vehicles, using carbon-fiber reinforced ABS on the Heron AM platform to deliver functional and aesthetically refined parts.
In the railway sector, Caracol worked with Alstom to apply large-format additive manufacturing for the production of complex, large-scale components. This provided a more agile and sustainable alternative to conventional fabrication processes, supporting both flexibility in design and material efficiency. In the design field, Caracol’s technology was showcased during Milan Design Week 2025 in the “PORTAL” installation, developed with Decibel and Vizcom. The project demonstrated how robotic LFAM can be used to create immersive, functional design pieces that merge advanced manufacturing with sustainability and creativity.
These diverse case studies underscore Caracol’s mission to drive innovation in industrial manufacturing, leveraging robotic additive technology to offer scalable, sustainable, and high-performance solutions across sectors.
source:caracol-am.com
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