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3D printed sailboat hull with recycled materials image

Caracol demonstrated the potential of large-format additive manufacturing in the marine industry by producing the Beluga sailboat hull using recycled composite materials. The project showcases how LFAM can enable the creation of large, functional structures with improved sustainability and reduced production time.

Beluga is the world’s first 3D printed sailing boat manufactured in a single piece using MyReplast™ recycled material, developed in collaboration with NextChem (Maire Tecnimont Group).Caracol-beluga-printing-3d

Robotic LFAM production with recycled polypropylene

To challenge traditional boat manufacturing methods – typically based on molds and non-recyclable materials like fiberglass – Caracol used its robotic LFAM system to produce the hull as a single monolithic component.

The structure was printed using recycled polypropylene reinforced with 30% glass fiber, combining lightweight properties with structural performance suitable for marine applications. The system’s multi-axis capabilities allow flexible extrusion angles, enabling the production of complex geometries, including hollow and suspended structures.

Production data

  • Technology: LFAM robotic system (Heron AM)
  • Material: Recycled PP glass fiber (MyReplast™ rPP GF)
  • Application: Sailboat hull
  • Production approach: Single-piece print, no molds required
  • 3D printing time: ~40 hours

This approach enables high-speed production while maintaining design flexibility and structural integrity.

Benefits and industrial value

The Beluga project highlights the advantages of combining LFAM with recycled materials for large-scale applications:

  • Sustainable production: Use of upcycled materials from plastic waste streams
  • Reduced environmental impact: Elimination of molds and minimized material waste
  • Fast production: Full-scale boat printed in approximately 40 hours
  • Design freedom: Ability to create complex, lightweight, and hollow structures
  • Process simplification: Single-piece manufacturing without assembly
  • Material innovation: Demonstration of high-performance recycled polymers in structural applications

This project proves that recycled polymers can be effectively used for advanced, load-bearing applications, opening new opportunities for sustainable manufacturing in the marine industry and beyond.Caracol-beluga-printing-3d_2

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