Feasibility Study of Prototype Naval Hull Designs Using Large Scale Additive Manufacturing

A large format additively manufactured (LFAM) model of the Pre-Contract DDG 51 class destroyer was co-designed with U.S. Navy and fabricated by Airtech International Inc. to meet tow model requirements. The model was then tested for resistance and body deformations in a calm-water tow-tank resistance test at NAVSEA Carderock. The results of testing were compared to a geometrically similar model constructed of fiberglass to assess the accuracy and feasibility of additively manufactured models for future testing purposes. The models were measured dimensionally by laser scanning technology prior to functional testing and the dimensional accuracy of the ship model was found to be 3x more accurate than previous fiberglass hull models.  A significant savings in cost and time-to-procure the model has been demonstrated with model fabrication time drastically reduced and cut in half for LFAM.  Testing was concluded with successful demonstration and approval to utilize LFAM manufactured tow models in the future. Verifying the validity of DoD requirements can be quickly realized and tested with LFAM.