Thyssenkrupp Marine Systems: The Digital Shipyard

The submarine goes back to antiquity. Legends, as depicted in a 16th-century illustration by Mughal poet Amir Khusrau, depict Alexander the Great descending into the sea via the primitive submersible of a diving bell. 

One of the earliest official submarines was designed by the American David Bushnell in 1776.

Called ‘The Turtle’ it was a hand-powered, egg-shaped device capable of independent underwater operation with screws for propulsion.  ‘The Turtle’ could only accommodate a single man.

Today, a typical military submarine can accommodate anywhere from 50 to 200 people.

Submarines have evolved into colossal and sophisticated machines, thanks to the invention of new propulsion systems, sonar and fuels. 

The world’s biggest today is the Russian BS-329 Belgorod, a special-purpose unit and carrier of 2M39 Poseidon nuclear torpedoes.

Undergoing significant advancement during their deployment in World War I, World War II and the Cold War, submarines operated as agents of hidden warfare, tools of subterfuge and nuclear deterrents. 

However, not all submarines are designated for military use. Submarines are essential tools in deep ocean exploration, furthering scientific research into underwater ecosystems and marine life. 

Manufacturing submarines is a complex process, marked by critical safety and efficiency considerations. 

The ocean is a hostile environment with insane pressures- quite literally.

By every 10m you descend, pressure increases roughly by one atmosphere. At the deepest point, approximately 11 kilometres down, the pressure is equivalent to an elephant standing on your little toe.

If submarines aren’t reinforced and built properly, as we saw with the infamous Oceangate Titan submarine, the consequences can be catastrophic.

A world leader in producing dependable, high-quality submarines is Thyssenkrupp Marine Systems. 

Supplying submarines for coastal and open-ocean operations to the navies of 20 countries across the globe, ThyssenKrupp strives to continually develop and advance new underwater and naval surface technologies.

Critical to this advancement has been digital transformation, which Thyssenkrupp has fully embraced through its digital shipyard.

Here’s how the company is innovating in two key areas- additive manufacturing and virtual reality- and why these tools help create superior, safer and more efficient submarines.

AR: From paper to projection 

Augmented reality plays a critical role in Thyssenkrupp Marine Systems' approach to engineering, design and construction.

For every submarine that’s made, 50,000 welded parts have to be spatially positioned during construction- typically requiring hundreds of 2D drawing sheets containing design documents.

With augmented reality, these documents are no longer needed. Instead, the inspection, marking and assembly of parts and objects can be done via virtual overlay.

Utilising Microsoft’s HoloLens smart glasses, ThyssenKrupp technicians interact with 3D virtual models of key parts and items, as opposed to viewing static 2D drawings.

For the maritime industry additive manufacturing has substantial applications and is already having a transformative impact.

“It’s certainly still pioneering work, but the breakthrough has been achieved,” says Stefan Lengowski, Senior Project Engineer (PLF) at ThyssenKrupp Marine Systems.

“Digitalisation can be experienced here and now. For me, the question about possibility no longer arises. Instead, I ask: Where else is it possible and applicable?”

AR glasses enhance quality control by enabling the comprehensive documentation of build status and early error detection- keeping technicians safer, as potential problems or risks can be identified and addressed sooner. 

The glasses facilitate more precise placement of parts, improving accuracy and reducing overall construction time through detailed 3D CAD models welding points, which are marked and tasks are tracked with status updates.

This improves communication, precision and efficiency, speed and refining the submarine construction process. 

Thyssenkrupp plans to integrate AR into its remote assistance and onboard documentation process, to streamline its processes and enhance the immediacy of its services.

3D Printing: quicker parts& projects  

Additive manufacturing is proving transformative for the maritime industry.

The US Navy has turned to the method to keep its submarine plans on track and the technology is being implemented by some of the biggest manufacturers in the world. 

Thyssenkrupp has integrated additive manufacturing across various sectors to enhance the speed and efficiency of production. In the maritime industry, the company has partnered with Wilhelmsen to provide 3D-printed maritime spare parts.

Driven by the goal to produce rapid and cost-effective 3D-printed submarine components, Thyssenkrupp has established a specialist team in Kiel. 

Here, they’re creating components geared towards the local fjord, with standard parts made via additive manufacturing installed in submarines today. Other parts installed include tubes and printed steel components like the housing cover of a ventilation system.

Additive manufacturing has been famously used to produce ship hulls and anchors as well. 

Production costs can be reduced through 3D printing, especially for complex components with low volumes. When producing a hydraulic block for a submarine, 83% of the weight can be saved through additive manufacturing, increasing submarine space and making work easier for staff.  

To produce a hydraulic block for a submarine, for example, 83% of the weight can be saved – from 14 to 2.1kg.

This not only means more freedom in the use of the available space on a submarine but also makes everyday work easier for production staff.

“3D printing opens up new potential for us,” says Alexander Orellano, former COO of Thyssenkrupp Marine Systems

“We no longer have to consider the limitations of conventional production methods everywhere in our design work.”

ThyssenKrupp’s newly opened TechCenter Additive Manufacturing in Mülheim an der Ruhr, Germany, facilitates the design and printing of metal and plastic parts via 3D printing. These parts feature complex, simultaneously lightweight and durable structures that can’t be achieved via traditional manufacturing methods. 

Technologies like sintering and selective laser melting build parts layer by layer from CAD files, eliminating the need for conventional die-making and tools.

Typically, sourcing and manufacturing maritime spare parts comes with long lead times and high costs. This collaboration quickly, efficiently and safely supplies parts, removing consequences associated with loss, reducing the need for high stock levels and creating more resilient supply chains. 

Thyssenkrupp uses 3D printing for internal projects, such as developing a heat-resistant probe for gas sampling in cement furnaces. These projects demonstrate the ability to produce specialised components with integrated features that enhance performance and durability​ (3D Printing Industry)​.

The advancement in both these areas is part of Thyssenkrupp's broader strategy to digitise and optimise manufacturing operations.  

As the digital shipyard continues to grow, so will the innovation and advancement we see across the maritime space.

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