The smartBOND project focuses on developing technological and organizational solutions to establish an adhesive bonding technology in shipbuilding. The aim is to increase product quality, productivity and create healthy and attractive working conditions. This project contributes to the sustainability goals through more efficient and environmentally friendly shipyard processes as well as the increase in lightweight construction and the resulting lower emissions in ship operations.

The fields of application relate to both joining and automation technology and are intended to create innovations in both areas. This includes a basic solution for the automated surface treatment of different materials, the automated application of adhesives as well as a portable automation solution and a mobile robot system, which results in a wide range of applications.

The strategic goals of this research program include increasing productivity and quality, high reproducibility of automated production processes, the associated reduction in throughput times, the development, testing and processing of new materials as well as increasing networking and digitalization (SMART FACTORY) through real-time evaluations and analyzes of data. This achieves a level of process automation that has never been achieved before in shipbuilding. The flexible use is particularly innovative due to the sensor-supported, semi-manual operation, which enables the shipyard worker to program the gluing task quickly and easily and which has not previously existed in either gluing technology or shipbuilding.

Integrated into the “Maritime Agenda 2025” to strengthen the maritime economy, this project is focusing on securing and expanding technological leadership for welding in special shipbuilding. The potential of maritime digitalization is investigated and resource-efficient production methods strengthened in order to advance the development of smart technologies and maritime digitalization. This research focus is intended to ensure shortened processing times and a reduction in error rates while at the same time improving product quality.

The aim here is to take a holistic view of the welding task of prefabrication for special shipbuilding and to develop a self-learning, AI-based manufacturing technology. The goal is to provide an application-oriented demonstration of the technological possibilities through process and market analyses, the development of hardware and software components and the integration with self-learning methodology. The resulting concepts of which form the basis for short-term implementation to ensure the international competitiveness of German shipbuilding. The focus here is on the productive and distortion-reduced production of modules and complex assemblies.

MEYER WERFT creates the basic process analysis for the project for the shipbuilding application and formulates the requirements for AI control, sensor technology, welding process and component distortion. The project then works on the development of a novel laser beam source, a welding strategy based on an AI development, the development and construction of an integrated processing head for a flexible automation solution, welding tests for basic development in the welding process in the shipyard environment, and the AI development of the adaptive, self-learning control technology including their testing in a test facility and validation through welding tests on realistic structural components. Finally, the overall system development is optimized and transferred to the prototype application as well as a concept development for future implementations.

This project is building the base for 3D-foam printing of large scale objects based on granulated feedstock like bio-based PLA and TPU as substitutes for GRP, Gypsum, and/or MDF for marine applications. It is aiming for a globally unique database of foamed bio-based thermoplastics that enable mould-free printing and most accurate modelling, while taking into account mechanical recycling. The substitution of synthetics with bio-based thermoplastics will lead to reductions of the environmental footprint.

The taken approach is to overcome challenges through producing end-user defined applications on industrial scale equipment by using appropriate materials and processes. The demonstrators will be tested against existing synthetic thermoplastics-based components to demonstrate the lower environmental footprint as well as competitive cost levels, and the most suitable component specific sustainability attributes will be identified by the end-user partners.

By using 3D-printing, the project is considering to replace existing Gypsum and/or MDF applications with sustainable bio-based thermoplastics. Additionally to the environmental aspect, shapes and geometries are very important and 3D-printing enables a great variety of different forms. The use cases of this project will meet or exceed the performance of current production processes and fossil-based materials to improve the environmental footprint.

To achieve climate neutrality in the cruise industry, the development of new, innovative energy systems is of central importance. Both the changing regulations and the attractiveness for customers require a transition to clean and efficient systems. Fuel cell technology with integrated fuel reforming combined with batteries is a key source of innovation, with MEYER WERFT leading the research for maritime application of this technology. Fuel cell solutions for maritime applications have been developed for many years and the yard is a pioneer in the use of new fuels such as methanol and LNG (and SynGas in future), which will enable the yard to offer highly efficient and emission-free passenger ships for all relevant fuels in the future.

Building on the findings of the previous project Pa-X-ell2, a concept for a cruise ship with a hybrid energy system and LNG/SynGas, which is based entirely on fuel cells and batteries, is being developed. The aim here is to develop a novel shipbuilding infrastructure, thermal and electrical integration of various systems as well as security technology that ensures full hotel load in a hybrid energy system.

The realization of a complete energy supply for passenger ships with fuel cells in a hybrid energy network with a non-fossil, environmentally friendly fuel offers a major developmental step towards low-emission and energy-efficient cruises and represents a major milestone on this development path.

A key aspect of saving fuel and the associated reduction of CO2 emissions on cruise ships is reducing weight. For this reason, the MEYER WERFT has long been using large-scale lightweight construction with special requirements for local support structures. Due to these individual requirements and the associated varying material thickness, it is necessary to further develop the welding processes, which can only be carried out automatically to a limited extent on conventional systems, and to use new, highly efficient welding processes. Especially in view of globalization and growing competition, innovative and efficient joining technologies in the manufacturing of ships are absolutely necessary in order to maintain the leading position of the German maritime manufacturing industry.

In this project, high-performance laser beam welding of thick sheets in particular is being developed in a process-reliable manner, as well as a corresponding system technology for industrial production plants. The resource efficiency and the ecological aspect of the production of maritime components should be increased by substituting conventional arc welding processes and laser beam-arc hybrid welding processes. Quality assurance in the form of digital twins (smart production) is of fundamental importance to ensure consistently high and defect-free weld seam quality. In addition to increasing efficiency and cost-effectiveness, the goals are also to reduce energy and resource consumption and manufacturing costs, which are achieved through adapted beam shaping, higher efficiency and shorter process times.

Following the research project, an existing panel line will be retrofitted for high-performance laser beam welding for various sheet metal thicknesses.