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A new era of custom luxury yachts, powered by robotic LFAM image

Robotic LFAM platform Heron AM brings large-scale additive manufacturing into luxury yachting production, enabling bespoke marine components with premium quality, faster delivery, and enhanced design freedom, through the collaboration between Caracol and Treddy.

The luxury yachting sector is increasingly shaped by the demand for highly customized, high-performance components, delivered without compromising production speed, sustainability, or process flexibility. Within this context, Caracol leveraged its Heron AM robotic LFAM platform to manufacture a large-scale yacht hard top. This approach made it possible to completely eliminate traditional tooling and molds, reduce assembly steps, and unlock unprecedented design freedom. By integrating complex geometries and bespoke solutions directly into the manufacturing process, robotic LFAM overcomes the limitations of conventional composite production, enabling greater creative flexibility while ensuring the structural integrity and premium surface quality required in luxury yachting.Caracol-lfam-robotic-hard-top-luxury-yacht1

The project demonstrates that additive manufacturing is now a mature, production-ready technology, no longer limited to prototyping, even for structural components such as hard tops, characterized by large dimensions and a high degree of customization. The development was carried out in collaboration with Treddy, a strategic partner that supported design definition and process optimization, further reinforcing Caracol’s collaborative and LFAM-ecosystem-driven approach to industrial innovation.

Process data:

  • System: Heron 300 with HF extruder
  • Material: ABS + 20% glass fiber
  • Nozzle diameter: 5 mm
  • Component dimensions: 2300 × 1600 × 870 mm
  • Weight: 120 kg
  • Print time: 22 hours
  • Post-processing: sanding and painting

Caracol-lfam-robotic-hard-top-luxury-yacht3

When customization becomes a competitive advantage

The adoption of Heron AM delivers tangible benefits in luxury yacht production, particularly for custom components such as hard tops and superstructures, by simplifying manufacturing workflows through mold elimination and fewer processing steps. This results in faster design-to-production cycles and a greater ability to respond to customization requirements, even for large and geometrically complex components. From an industrial perspective, robotic LFAM enables shorter lead times, optimized costs, and more sustainable production processes. In addition, the reduction of manual operations and post-processing activities significantly improves process reliability and scalability.Caracol-lfam-robotic-hard-top-luxury-yacht2

Key production benefits:

  • 80% lead time reduction
  • 25% costs reduction
  • 10% waste reduction

Thanks to Heron AM, Caracol positions robotic LFAM as a robust and scalable production technology for the marine industry. The system enables the manufacture of fully customized hard tops and structural components without the need for tooling or molds, accelerating production through optimized workflows, improved repeatability, and enhanced material efficiency, supporting more sustainable yacht manufacturing.Caracol-lfam-robotic-hard-top-luxury-yacht4

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