Manufacturing is at a crossroads. The sector faces mounting pressure to cut emissions and operate more sustainably, while also operating within fragile global supply chains, exposed by pandemic shutdowns and geopolitical disruptions, that threaten reliability and growth. Navigating these forces requires reconsidering how products are engineered, manufactured, and serviced. In this context, localised, flexible production is no longer just a competitive advantage, it is becoming a necessity explains Dr Misael Pimentel Espirindio e Silva, Direct Energy Deposition (DED)-Arc Theme Lead, Senior Additive Manufacturing Engineer at Digital Factory at the National Manufacturing Institute Scotland (NMIS).
One technology at the forefront of this shift is large-scale additive manufacturing (LSAM). Different from traditional casting, forging, and forming, LSAM enables layer by layer component manufacturing using advanced welding and other deposition techniques, creating structures that can span several metres in length. As well as improving efficiency, the technology strengthens supply chain security by allowing critical parts to be produced closer to where they are needed, reducing dependence on distant suppliers, minimising delays, and lowering emissions from transporting heavy items overseas.
Case study: resilience at sea
The potential of LSAM has already been demonstrated in shipbuilding, one of the world’s most traditional industries. In a project known as Marine Vessel Lightweighting 2 (MariLight 2), led by Malin Marine Consultants in collaboration with the National Manufacturing Institute Scotland (NMIS), explored whether additive methods could minimise reliance on manual fabrication processes for essential ship components. Lloyd’s Register, BAE Systems, Caley Ocean Systems (part of the Pryme Group), Siccar, Altair, and Hexagon Manufacturing Intelligence (HMI) also supported the research.
During the project, NMIS engineers helped redesign and manufacture a pipework tapping ring, a part central to ship safety and reliability. Using LSAM, specifically wire-arc additive manufacturing (WAAM) and topology optimisation, they achieved a 13% reduction in weight, lowered production emissions by 10%, and cut manufacturing time by 90% compared with conventional techniques. The component passed rigorous hydrostatic and leak testing and received certification from Lloyd’s Register, proving its suitability for use at sea.
The team also investigated larger structures such as bilge pump foundations and bulbous bows, which typically require fabrication in confined spaces that can be deemed unsafe for welders. By moving from manual to automated production, LSAM not only reduced health and safety risks but also delivered weight savings of up to 53%.
Together with additional NMIS research into compressor remanufacturing, showing how similar methods can extend the life of complex, high-value parts, the project highlighted LSAM’s wider potential. They herald a future where manufacturing is defined not by volume, but by smart and strategic use of resources already in circulation, embedding resilience into the supply chains that modern industry depends on.
Crucially, this proves that components like the tapping ring (often sourced internationally) can now be manufactured to local standards when coupled with robust quality control measures. This capability helps shipyards maintain operations even when global supply chains are under strain, demonstrating how LSAM contributes not only to efficiency but also to long-term resilience.
Overcoming adoption challenges
While LSAM offers clear benefits, scaling up its adoption presents significant challenges. These include skills, where industries will need to invest in upskilling staff in areas such as digital design, welding automation, and additive processes, and also evolving workflows – particularly in sectors governed by stringent safety regulations, where extensive testing and certification are essential before new methods can be deployed. Developing shared standards and best practices will be critical to accelerate adoption and ensure that parts produced locally meet global quality expectations.
Another consideration will be the investment required to make LSAM a reality. Equipment costs are significant, especially for advanced technologies and larger build volumes. However, technologies such as wire-arc AM (WAAM) are typically less expensive than powder-based AM systems, offering a more economical entry point.
Opportunities across industries
The opportunities for LSAM extend well beyond shipbuilding. In aerospace, for example, it can allow manufacturers to produce large structural components, tooling, and even repair components domestically, reducing downtime and reliance on international suppliers, while enabling lighter, more optimised designs. In the automotive sector, LSAM accelerates the production of tooling, body panel moulds, and large prototypes, reducing cost and time required for prototyping and low-volume parts. In energy and renewables, it creates possibilities for manufacturing or repairing large-scale components such as turbines, pressure vessels, and other safety-critical infrastructure to required industry standards, often at a scale and complexity that can be difficult or uneconomical to achieve with traditional manufacturing techniques.
This growing capability aligns closely with the UK Government’s newly launched Defence Advanced Manufacturing Strategy, which recognises additive manufacturing as a key enabler for strengthening sovereign capability and ensuring supply chain resilience in critical sectors. Within this, LSAM, particularly in areas such as direct energy deposition (DED) and WAAM, will play a pivotal role in delivering components faster, locally, and to the high integrity standards demanded by defence applications.
Across these sectors, the benefits are not only shorter lead times and lower emissions, but also greater design freedom, improved part performance, and the ability to keep high-integrity equipment in service for longer. Taken together, these opportunities show how LSAM can reinforce supply chains while opening the door to smarter, more sustainable ways of working.
Towards a new industrial future
While progress has been encouraging, LSAM remains a relatively young technology. Scaling it for heavy industry will require continued investment, rigorous testing, and shared standards. For the UK, with its established engineering base and ambition to compete globally on both cost and resilience, the opportunity is clear. Large-scale additive manufacturing may be proving itself in the shipyard, but its true potential lies in reshaping industries across the board, creating a manufacturing ecosystem that is leaner, more agile, and better prepared for the shocks of tomorrow.
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