The maritime industry is on the cusp of a design revolution, and a £700,000 project led by Exeter’s Rapid Fusion is at the helm. This isn’t just another tech pilot—it’s a full-scale assault on the traditional design-to-manufacturing cycle, armed with generative AI and large-format additive manufacturing. The goal? To slash costs, accelerate timelines, and boost efficiency by up to 50% while cutting emissions. This is GenDSOM, and it’s a game-changer.
At the heart of the project is a crew transfer vessel (CTV) from BYD Naval Architects, serving as the testbed for Rapid Fusion’s Apollo robotic 3D printing system. Apollo isn’t your average printer—it’s a turnkey large-format solution that churns out engineering-grade polymers at speeds nearly 200 times faster than conventional FDM systems. And it’s not just about speed; it’s about cost savings, too, using polymer pellets instead of filament. This isn’t just about printing parts; it’s about rethinking how vessels are designed and built from the ground up.
Martin Jewell, Rapid Fusion’s chief technical officer, cuts to the chase: “Additive manufacturing has expanded design freedoms, but scalability remains constrained.” GenDSOM tackles this head-on with a modular strategy, breaking designs into manufacturable subcomponents that play nice with both traditional and additive manufacturing processes. The team is embedding manufacturing constraints—think building envelope limits, support structures, and material compatibility—right into the design phase. This isn’t just about making things; it’s about making things right, the first time.
Shahroz Khan, CEO of Compute Maritime, doesn’t mince words: “The maritime industry urgently requires evolved, smart design frameworks that balance sustainability with operational and economic viability.” GenDSOM isn’t just a project; it’s a survival strategy. The team aims to cut design costs by 10%, speed up design cycles by 20%, and boost overall efficiency by 50%. And it’s not just about efficiency—it’s about decarbonisation. This project aligns squarely with the UK’s 2025 Maritime Decarbonisation Strategy, targeting emissions reductions of 30% by 2030 and 80% by 2040.
Jami Buckley, CEO of BYD Naval Architects, highlights the project’s unique ability to generate solutions that would otherwise be out of reach for designers relying solely on domain expertise. This is where generative AI shines, particularly Compute Maritime’s NeuralShipper. It’s not just a tool; it’s a copilot, guiding designers through complex challenges like next-generation propulsion technologies or alternative fuels.
Dimitri Ponkratov, marine director at Siemens Digital Industries Software, puts it bluntly: “This project represents a new leap within maritime design.” By bringing all the digital elements—design, performance, and manufacturability—into one loop, GenDSOM is unlocking a new paradigm. It’s not just about designing better vessels; it’s about designing smarter, faster, and more sustainably.
Over the next seven months, the consortium—Rapid Fusion, Compute Maritime, BYD Naval Architects, Siemens Digital Industries Software, and the University of Southampton—will combine their expertise in AI, design, simulation, optimisation, and manufacturing. Supported by HP Z Workstations’ compute power, they’re not just pushing boundaries; they’re redrawing them.
Tahsin Tezdogan, professor of marine hydrodynamics at the University of Southampton, underscores the significance: “Intelligent tools like NeuralShipper can generate highly efficient, unconventional hull shapes, supported by advanced simulations that accurately assess performance.” GenDSOM isn’t just about incremental improvements; it’s about addressing the core challenge of designing more efficient vessels.
This project is more than a collaboration—it’s a blueprint for the future of maritime design. By embedding AI-driven intelligence into the design process and leveraging advanced manufacturing techniques, GenDSOM is setting a new standard. It’s not just about keeping up with the industry; it’s about leading the charge. And in a sector historically anchored in tradition, that’s exactly what’s needed.