In 2022, Hyperion Systems produced the Southern Hemisphere’s first full-scale 3D-printed boat — a three-metre vessel manufactured in a continuous 36-hour print. The project served as an early validation of Large Format Additive Manufacturing (LFAM) in maritime applications, demonstrating both the possibilities and the practical challenges of the process.

The vessel was built using polypropylene reinforced with glass fibre, selected for its balance of strength, durability, and compatibility with LFAM. This choice also reduced the need for conventional moulds and tooling, showing how additive methods can streamline production and lower material waste.

Rethinking Boatbuilding

Traditional boatbuilding relies heavily on moulds, which can be expensive and restrictive. LFAM offers a way to bypass these constraints, allowing for greater design flexibility and faster prototyping while cutting down on waste. The approach also supports the use of recycled and sustainable materials, making it an attractive complement to existing manufacturing methods.

Lessons and Next Steps

This project was less about replacing shipbuilding traditions and more about testing what LFAM can contribute. By collaborating with builders, designers, and material specialists, Hyperion continues to refine the technology and identify where it adds the most value.

The printed vessel stands as a proof of concept — a step towards more adaptable and sustainable production methods in maritime engineering.