Austal turns to print

WEST Australian based shipbuilder, Austal has thrown its weight behind a research program into making greater use of industrial grade 3D printing for components that would normally be cast or machined.

The additive manufacturing collaborative research project is aimed at accelerating the adoption of additive manufacturing across Australia’s maritime and defence supply chain, in a move the shipbuilder says will help industry make faster, more informed decisions about where the technology delivers the greatest value.

The $600,000 project brings together Austal, Curtin University and the Additive Manufacturing Cooperative Research Centre (AMCRC) to develop an industry‑ready assessment framework capable of evaluating thousands of vessel and supply chain components against operational, commercial, technical and regulatory criteria.

The 18‑month program is designed to address one of the sector’s most persistent barriers: knowing which parts are genuinely suited to additive manufacturing, and where investment will deliver measurable improvements in lead times, resilience and sovereign capability.

Austal head of research and development, Sam Abbott, said the challenge for industry “is no longer proving that additive manufacturing works, but identifying where it delivers the greatest advantage”.

“This framework will help us quantify the demand for additive manufacturing across maritime and defence programs, allowing industry to make better investment decisions, build more resilient supply chains and accelerate the uplift of Australia’s advanced manufacturing capabilities,” Mr Abbott said.

Austal will draw on its experience as prime contractor for the United States Navy’s Additive Manufacturing Centre of Excellence, providing global insights and real‑world production data to support the research.

Curtin University will lead the development and validation of the framework, ensuring it reflects real vessel configurations, maintenance cycles and supply‑chain realities. Research lead Dr Karl Davidson said combining engineering, operational and commercial considerations into a single methodology would help manufacturers move more quickly from opportunity identification to implementation.

AMCRC managing director Simon Marriott said the project addresses a critical gap in industry capability: selecting the right components for additive manufacturing.

“Many organisations understand the potential of additive manufacturing, but struggle to determine where it makes commercial and operational sense,” Mr Marriott said. “This project will deliver a practical solution that helps industry identify high‑value opportunities, prioritise investment and build confidence to scale adoption.”

Additive manufacturing — often described as industrial‑grade 3D printing — builds parts layer‑by‑layer from digital models rather than machining or casting them from bulk material. For shipbuilders and sustainment providers, the technology offers several potential advantages:

• Reduced lead times for critical spares and low‑volume components

• Improved supply chain resilience, particularly for parts sourced from overseas

• On‑shore or on‑vessel production of selected components

• Repair and remanufacture of worn parts using directed‑energy deposition

• Complex geometries that cannot be produced through conventional machining

• Digital inventories that reduce the need for physical stockholding

However, not every component is suitable for additive manufacturing. Suitability depends on factors such as material type, certification requirements, geometry, load conditions, production volume, and the commercial cost‑benefit compared with traditional methods. This is why the framework is significant: it provides a repeatable, evidence‑based way to determine where additive manufacturing should be deployed.