Driven by the global wave of environmental sustainability, the shipbuilding and composite Marine industries are actively exploring low-carbon, high-efficiency development paths. Composite materials, with their outstanding physical properties and eco-friendly characteristics, have become a key material in this transformation process.

This article reviews the latest application trends of composite marine materials in shipbuilding and the marine industry, including lightweight design, decarbonization technologies, sustainable materials, and technological innovations. In response to changing market demands and global economic fluctuations, ship manufacturers continue to achieve product innovation and performance enhancement through composite materials.

From the rise of small personal watercraft to the eco-friendly retrofitting of large ships, the application of composite materials is becoming increasingly widespread. Meanwhile, the integration of advanced technologies such as 3D printing, carbon fiber reinforcement, core material molding, and smart navigation has opened a new chapter for the use of composite materials in shipbuilding and the marine industry.

As consumer demand slows down in 2023-2024, shipbuilding and marine vessel manufacturers continue to focus on utilizing composite materials to achieve decarbonization and introduce new technologies.

Slowdown in Shipbuilding Transactions

According to the National Marine Manufacturers Association (NMMA), based in Washington, D.C., released its 2023 statistics, forecasting a 1%-3% decline in new powerboat retail sales, totaling 258,000 units. While sales of most powerboat categories have dropped by 5%-25%, the retail sales of personal watercraft—small, entry-level vessels that can accommodate up to three people—have increased by 20%-25%, with an estimated 85,000-90,000 new units expected to be sold in 2023. “Due to the rise in interest rates and inflation in 2023, we are seeing more yacht consumers becoming price-sensitive and opting to wait before purchasing their next yacht. In the meantime, they are choosing to buy personal watercraft,” said Frank Hugelmeyer, President of the NMMA.

Composites Transforming Maritime Sustainability

The NMMA predicts that new boat sales in 2024 will remain level with 2023, considering the impact of persistently high interest rates and unstable consumer confidence during the election year. At the same time, the NMMA points out that powerboat manufacturers continue to focus on utilizing emerging technologies to launch innovative products, including decarbonizing recreational vessels through sustainable marine fuels, hydrogen (H2), electricity, and hybrid propulsion systems.

This market outlook was confirmed by BoatsGroup.com, a global online yacht market group, in its market report from August 2024. The report shows that global sales in the first half of 2024 declined by 9.1%, primarily due to a 12.4% drop in used boat sales, while new boat sales increased by 5.3%. The report once again highlighted high interest rates and inflation, explaining why small boats (less than 26 feet in length) have become the main driver of new boat sales, with over 12,000 units sold in the first half of 2024.

Composite Marine Boat Construction Trends

A report released in August 2024 also analyzed the top trends in the market, including sustainability, materials and technology innovation, customization and unique features, and affordability:

• Sustainability: Electric and hybrid-powered boats are becoming increasingly popular due to their quieter operation, lower emissions, and reduced maintenance. These vessels are often made using composite marine materials and equipped with solar panels and smart technologies to enhance operational efficiency.
• Materials and Technology: The use of carbon fiber is growing due to its lightweight properties, while the adoption of bio-based and recyclable composites is also increasing. Additionally, emerging trends are rising, such as smart navigation systems, advanced anti-collision safety features, and greater integration of autonomous technologies and artificial intelligence, offering functionalities like automated docking and predictive maintenance.
• Customization: Yacht enthusiasts seek personalization through exterior colors and graphics, as well as tailored technology and performance options. This includes enhancing space and usability based on individual preferences.
• Affordability: The market remains highly price-sensitive, which supports the continued preference for outboard motorboats and personal watercraft, with these boats seeing continued sales growth compared to other segments.

1. Ship Building Trends

According to an article in International Shipping News published in September 2024, the most significant trend for large maritime vessels remains the reduction of carbon footprints. This includes the development of new fuels, fuel efficiency technologies (such as optimized hull shapes and air lubrication systems), and zero-emission technologies like hydrogen and wind propulsion. Experts predict that the widespread use of wind propulsion and alternative fuels is crucial for achieving the International Maritime Organization’s (IMO, London, UK) targets. These targets include:

• Achieving net-zero greenhouse gas (GHG) emissions by 2050, effectively ending the use of fossil fuels
• Reaching a 20% reduction (with efforts to achieve 30%) by 2030 as a phased goal
• Achieving a 5%-10% adoption rate of near-zero/zero GHG emissions technologies and fuels by 2030 to support the above goals
• Reaching a 70% reduction (with efforts to achieve 80%) by 2040 as a phased goal

Other trends include the digital transformation of the shipping industry and the increasing number of autonomous vessels, which has driven demand for cybersecurity and data standards, as well as the use of automation, machine learning, and cloud-based systems in production and operations.

A 2023 report on the use of composite materials in EU shipyards reaffirms these trends and highlights how they have driven increased interest in the use of composites. The report discusses a survey conducted as part of the FIBRE4YARDS project, which asked shipyards about their experience and interest in advanced composite boat construction technologies. These technologies include adaptive molds, automated tape/fiber laying, curved pultruded profiles, additive manufacturing (AM), hot stamping, modular and serialized shipbuilding, and production digitalization.

Among the 426 contacted shipyards, 39 responded. These shipyards were categorized based on the types of vessels they produce (see chart on the right), with most producing multiple types of vessels. Notably, 21% of shipyards produced passenger + service vessels or special-purpose + service vessels. As shown in the chart, 77% of the surveyed shipyards either use composites in-house or through subcontractors.

While the most commonly used materials and processes were mostly as expected, it was surprising to see such a high ranking for the use of carbon fiber and epoxy resin.

2. 3D Printing Technology in Composite Marine

The use of 3D printing composites in shipbuilding and marine applications continues to grow. In March 2024, CEAD Group (Delft, Netherlands) highlighted several new 3D printing developments in the shipbuilding industry. One of these is a 3D-printed autonomous ferry designed for the 2024 Paris Olympics.

The ferry was commissioned by a Dutch shipyard (located in Hardinxveld-Giessendam, near Rotterdam) and was manufactured by the nearby printing service provider 10XL using a robotic 3D printer. 10XL has also partnered with Impacd Boats (Woodenend, Friesland, Netherlands), which is currently using recycled materials to 3D-print the hulls of its electric catamaran sailboats. Founder Marike de Boer pointed out that each Impacd 3D-printed boat can be recycled up to eight times.

Since 2016, 10XL has been pioneering innovation in the field of large-scale additive manufacturing (AM) using recycled plastics. It has also been involved in other maritime projects, including large ship furniture and stealth underwater unmanned vehicles (UUVs) for naval use. After carefully researching and refining its technology in 2024, 10XL now claims to have full-layer temperature control, industrial-grade infill, and isotropic material performance. In October 2024, it delivered a new Felicity 1000 carp fishing boat model to Felicity Boats International (Franeker, Netherlands).

Although Impacd Boats and Felicity Boats primarily use unreinforced recycled plastics, CEAD machines typically use fiber-reinforced thermoplastic pellets in their extruders and can also work with continuous fibers. CEAD aims to ensure that 3D printing composites make progress in the marine sector and announced in October 2024 that it will open a Maritime Applications Center in Delft.

The center will be equipped with a 12-meter-long extrusion 3D printer designed specifically for producing hulls, along with several other large-format additive manufacturing (LFAM) machines (such as ATLAM and Flexcube). The center is intended to foster collaboration between maritime industry leaders and CEAD experts to develop large 3D-printed vessels and marine components, share knowledge, and advance progress in regulations, certification, and other areas. The first projects have been signed, with an industry event planned for the end of Q1 2025, and the official opening scheduled for Q3 2025.

CEAD’s extrusion heads are also used for faster and more sustainable production of boat model plugs. Rapid Prototyping (Budapest, Hungary) has been using CNC-machined polyurethane foam and hand-laid glass fiber-reinforced plastic (GFRP) to create molds for years. In 2020, the company acquired CEAD’s E25 robotic extruder, integrated it into its 4,850 × 2,635 × 1,460 mm gantry CNC machine, and began using the system to produce molds and prototypes made from polypropylene (PP) reinforced with 30% short glass fibers. According to company manager György Juhász, this has reduced labor time by up to 50% and shortened delivery cycles.

3. Carbon fiber Superstructures, Ship Bonding and Repair.

Another ongoing trend in the shipbuilding/marine applications sector is the use of carbon fiber to enhance lightweight construction, particularly in the cabins and superstructures. For example, Vabo Composites (Emmeloord, Netherlands) produced two lightweight carbon fiber composite marine cabins for a renowned Dutch sailboat manufacturer. In a press release, the company explained: “By using composites, we offer our customers an unmatched combination of strength, lightweight structure, and durability.”

3.1 StrengthBond and DuraBond offshore projects

Carbon fiber is also the preferred material for repairing large (e.g., 40 square meters) laminated/bonded composite patches for corrosion of steel vessels, including ships and offshore oil platforms. Stéphane Papoff, head of the Composite marine Materials Department at Bureau Veritas, Nantes, France, explained: “However, there is no standardized repair method for the primary structures in these maritime applications — wide flat plates.” To address this issue, Bureau Veritas collaborated with the industry partner alliance of the StrengthBond Offshore project (2019–2023).

The project developed a robust method for strength analysis of such repairs, including numerical tools for evaluating and verifying designs, surface treatment and manufacturing protocols, as well as physical testing. The latter included the development of a new equivalent interface specimen capable of characterizing multiple interfaces within the bonded composite repair patches. By the end of the project, more than 250 specimen tests and 115 numerical simulations had been completed, including fatigue testing of large specimens that underwent between 50,000 and 5 million cycles.

Papoff stated that carbon fiber is used for these repair patches because “if we used glass fiber, the thickness would be too large. However, we used a few layers of glass fiber between the carbon fiber and steel to prevent galvanic corrosion.” The patches use epoxy resin without adhesive and are post-cured at 80°C, with a total cycle time of 16 hours.

Two different manufacturing processes were tested: vacuum-assisted resin infusion and vacuum bag hand lay-up. The results showed that both methods had roughly the same strength. However, the strength of the repair patch with a long tapered joint design was 38% higher than that of the patch with a short tapered joint design.

In November 2024, the three-year follow-up project, DuraBond Offshore, was launched. This project will involve aging the specimens in water and hydrocarbons, as well as in high and low-temperature environments, followed by static and fatigue testing. Papoff said that through these tests, “we can assess the impact of the environment on the strength of the patches, allowing us to adjust safety factors and confirm long-term performance.”

3.2 Toray VARTM Ship Repair Technology

Carbon fiber supplier Toray Industries (Tokyo, Japan) has also been exploring bonded composite repair technologies for ships. In September 2024, Toray announced that it had received approval from the American Bureau of Shipping (ABS, Houston, Texas) for its Vacuum Assisted Resin Transfer Molding (VARTM) process, which is used for repairing carbon fiber reinforced polymer (CFRP) laminates.

This approval allows the VARTM process to be applied to ABS-certified vessels, reducing the time required for engineering review and verification. During the repair process, Toray’s carbon fiber woven fabric is applied to the steel structure’s surface. A vacuum bag is then placed over the fabric, and a cured epoxy resin is injected to bond the CFRP to the steel structure, restoring the strength of the corroded area.

4. Wind, Electric, and Hydrogen-Powered Propulsion Composites

In August 2024, UK-based wind propulsion company GT Wings announced a strategic partnership with KS Composites (Melton Mowbray, UK) to jointly produce its AirWing technology. AirWing is designed for commercial shipping and aims to reduce fuel consumption and carbon emissions by up to 30%, helping shipowners achieve significant fuel savings while meeting the strict environmental standards set by the European Union (EU) and the International Maritime Organization (IMO).

The first AirWing device is planned to be installed on a 124-meter cargo ship operated by Carisbrooke Shipping in the fourth quarter of 2024. In October 2024, GT Wings received funding from the UK Innovation Agency (Innovate UK) through the Smart Shipping Acceleration Fund (SSAF), which focuses on developing the technologies needed to decarbonize the UK maritime sector.

Composites are also key materials for lightweight electric boats and hydrofoils, often used to further enhance their performance. In August 2024, Artemis Technologies (Belfast, UK) announced the opening of its first U.S. office in response to strong interest in its products in North America. Artemis Technologies designs, develops, and manufactures 100% electric hydrofoils driven by its eFoiler system.

Artemis’ watercraft feature composite/metal hydrofoils and structures made from glass and carbon fiber composites. “The maritime industry is transitioning to more sustainable operations,” said David Tyler, co-founder of Artemis Technologies. This includes a large number of inefficient diesel-powered ferry systems currently operating on routes that traverse densely populated and often marginalized communities. “Ferry operators are increasingly realizing that they must adopt electric power to reduce emissions and modernize their fleets,” Tyler added. “We have a tried and tested solution to ensure this transformation can achieve commercial success.”

Meanwhile, Hexagon Purus (Oslo, Norway), through its wholly owned subsidiary Hexagon Purus Maritime (Ålesund, Norway), is developing and supplying Type 4 CFRP pressure vessels for hydrogen (H2) storage for a range of zero-emission marine vessels. In September 2024, the company announced it had secured a contract with Freire Shipyard (Vigo, Spain) to supply a set of compressed gas H2 storage tanks for a 75-meter vessel being built for Greenpeace.

The system is expected to be delivered in 2027. Hexagon Purus Maritime noted that providing green H2 for the maritime sector is crucial for reducing global greenhouse gas emissions. The company is developing several projects, and by 2050, green H2 is expected to meet up to 25% of global energy demand.

5. Continuing the Push for Sustainability

Sustainability in maritime applications is not limited to decarbonizing propulsion systems, but also includes lightweighting provided by composites and the search for lower energy consumption, reduced carbon emissions, and sustainable materials and processes. In an announcement celebrating 50 years of collaboration in September 2024, foam core and composite supplier Diab (Laholm, Sweden) highlighted the use of foam-core carbon fiber reinforced polymer (CFRP) structures by Norwegian shipbuilder Brødrene AA on its fast, energy-efficient ferries.

Diab noted that Brødrene AA had extended the vessel’s lifespan by using composites, maximizing durability and minimizing the need for replacements, thus lowering overall lifecycle costs. However, Diab also reported significant progress in reducing its materials’ carbon footprint, achieving a 50% reduction in emissions from 2016 to 2023.

A February 2024 article in CompositeWorld discussed several composite boat construction manufacturers and initiatives focusing on recycled and bio-based materials. This includes demonstrations of recycled composites using Arkema’s (Colombes, France) Elium thermoplastic resin, as well as efforts by ExoTechnologies (Douglas, Isle of Man) and its subsidiary The Ultimate Boats Co. (Clydebank, Scotland), and Innovation Composite Yachts (Les Sables d’Olonne/Vare, France) using basalt fiber, and Greenboats (Bremen, Germany) utilizing flax fiber.

Technical editor Hannah Mason also highlighted Greenboats in her October 2024 article titled “Developing Natural Fiber Technologies to Meet Industry Sustainability Needs.” Another company using basalt fiber is BRŪT Yachts (Antwerp, Belgium), which offers the 29GT hull made with 50% recycled materials sourced from Basaltex (Weverham, Belgium). Meanwhile, Italian company Northern Light Composites (nlcomp, Monfalcone) announced in July 2024 that it had secured over €500,000 in funding to accelerate the development and commercialization of its patented recyclable composite technology, Composite, including a new series of vessels for the European market. The company stated that this responds to the growing demand for environmentally friendly solutions and contributes to the more sustainable development of the yachting industry.

In November 2024, Sicomin (Chateauneuf-le-Martigues, France) introduced the Skaw (A) hydrofoil cruising composite yacht, built in collaboration with Skaw Sailing (Lorient, France) and composite boat construction manufacturer Shoreteam (Colombes, France). The composite yacht is constructed using Sicomin’s high-modulus GreenPoxy resin, including SR InfuGreen 171 for large part impregnation and SR GreenPoxy 170 for hand lamination and bonding of secondary structures. The company explained that these resins enabled Shoreteam to achieve a super-light displacement of 5000 kg and the high mechanical performance required for hydrofoiling.

MiniLab is an initiative launched in 2023 by Adrien Marchandise, co-founder and CTO of Avel Robotics (Lorient, France), aimed at advancing sustainability and reducing the maritime industry’s environmental impact. Avel Robotics is a pioneer in the use of automated fiber placement (AFP) to manufacture high-performance CFRP hydrofoils for IMOCA yachts (see CompositeWorld November 2022 travel article).

Marchandise described MiniLab as an open innovation ecosystem that connects public and private partners to collaboratively develop and test technologies through full-scale demonstration projects. “MiniLab has two aspects,” he explained. “One is as a collaborative platform, bringing together industry, technology centers, and universities to co-develop sustainable concept prototypes. The other is as a real-world testing laboratory, where partners can validate these prototypes in actual sailing conditions through the Mini 6.5-meter sailboat, numbered 754.”

MiniLab’s timeline includes projects such as achieving recyclable composite hydrofoils and building the next vessel entirely made of sustainable materials.

In 2023, Marchandise launched a collaborative project funded by MiniLab, Avel Robotics, and the technical innovation center Compositic (Plouharnel, France), aimed at evaluating different thermoplastic composite marine (TPC) materials. The first demonstration materials include carbon fiber-reinforced tapes supplied by Suprem (Monthey-Preles-Iverdun, Switzerland) and Victrex (Clevedon, UK), as well as thermoplastic foam from Diab, Noah Material. These materials will be used to make hydrofoils for the Mini 6.5 sailboat, which will be tested in the 2025 season. “I’ve integrated a lot of sensors into these components to measure how the materials perform in actual conditions,” Marchandise said.

At the same time, MiniLab has also launched another large-scale project funded by Avel Robotics and the Brittany region. “We’re developing a thermoplastic material with higher compressive strength,” Marchandise said. “Our goal is to start mass production to industrialize thermoplastic composite hydrofoils for larger sailboats, with the aim of producing the first set of hydrofoils for IMOCA-class yachts by 2026.”

In conclusion

The composite marine industry is undergoing a significant transformation, driven by the growing emphasis on environmental sustainability. Composite marine materials, with their lightweight and eco-friendly properties, are central to this shift, enabling both the shipbuilding and marine industries to innovate and adopt low-carbon, high-efficiency solutions. From the rise of 3D printing and carbon fiber to advancements in electric, hydrogen, and wind-powered propulsion systems, composite materials are playing a pivotal role in reshaping the industry’s future.

While the current market faces challenges, such as slowing consumer demand and economic uncertainties, the focus on decarbonization and the integration of new technologies continues to guide manufacturers. As they strive to meet stricter environmental regulations and improve operational efficiency, composite marine materials will remain a cornerstone of sustainable shipbuilding and marine innovations. Ultimately, the ongoing push for sustainability, along with breakthroughs in composite boat building materials and manufacturing technologies, promises to accelerate the industry’s journey towards a greener, more efficient future.