Moi Composite launched MAMBO (Motor Additive Manufacturing Ship), a fiberglass 3D printing ship, manufactured in cooperation with major industrial partners (Autodesk, Catmarine, Micad, Owens Corning, Osculati and UCINA) in order to overcome traditions The custom design and performance limitations of manufacturing and prove that 3D printing can make strong, lightweight and durable composite products.
MAMBO is made using Moi's proprietary process patented continuous fiber manufacturing (CFM) technology, which won the 2017 JEC Innovation Award, which combines the high performance of continuous fiber thermoset composites with the potential and advantages of the additive manufacturing process.
CFM technology uses continuous fibers (in this case, glass fibers), which follow a tool path generated by an intelligent planning software algorithm, deposited in a controlled manner from the head of the KUKA robot machine. This allows the creation of three-dimensional fiber-reinforced objects starting from digital CAD files, which have the same mechanical properties as unidirectional glass fibers, without the use of additional equipment or molds, and with less material waste. In this way, not only can you get prototypes, but you can also get real and functional objects, such as MAMBO.
The 6.5-meter-long motor boat, with a maximum beam of 2.5 meters, is constructed from a Y-shaped hull, inspired by the historic Arcidiavolo of Sonny Levi. On this basis, a single-shell structure with an organic and asymmetric shape is constructed, adapted to the function and design ideas, so that it does not have the constraints of ships made by traditional techniques (draft angle, undercut, hull and deck division, etc.). The upper part of the hull organically becomes the other parts of the boat: the symmetrical top of the boat changes, half becomes the console, and the other half becomes the ramp, taking the user to the deck where there is a drop-shaped sofa The sofa can be used as a driving seat and a leisure sofa.
Once the concept was clear and the execution project was executed, two unidirectional glass fiber parts were 3D printed using two anthropomorphic robots located at two physical locations 1500 km apart. One is located in Milan, the operational headquarters of Moi Composites, and the other is in the Autodesk advanced manufacturing plant in Birmingham, UK. It takes full advantage of the delocalization of production in additive manufacturing. After the 3D printing is completed, the parts are connected and laminated together, giving this challenging ship a life at a time.
Each individual part is laminated in a three-layer board with a PVC core, polyester resin and fiberglass fabric to form a layer of plating and reinforcement structure, and then connect them together. The production process is completed by the aesthetic decoration of the outer surface, and then the necessary marine equipment / accessories are assembled. MAMBO not only constitutes an example of a fully 3D printed boat using continuous fiber composite materials, but will also be the first object of this type of ship planned to be put into operation. It will be equipped with an outboard engine and will be launched in July 2020 to show how the technology is ready to produce items for the market, not just a prototype.
To start this ambitious project, Moi was supported by Autodesk, a software world company that provided tools for realizing a three-dimensional map of the hull and a robot based in the United Kingdom.
Catmarine is a shipyard specializing in the construction of catamarans. With its rich experience, it has transformed various parts of digital production into finished ships.
Micad, a nautical design studio, is active in the field of research and technological innovation and challenges the engineering design of Mambo complex structures.
Last but not least, Owens Corning provided glass fiber reinforced materials, and an Italian marine parts company Osculati provided accessories that could adapt to the entire hull curve and design.