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.

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.

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.

Wire Arc Additive Manufacturing (WAAM) is a primary forming manufacturing process that enables a comparatively quick production of large-format metal components and can also be used to create complex geometries using robot support. The respective welding filler-/welding gas combination influences the microstructural properties, such as the resulting structure and the grain sizes. This in turn influences the resulting mechanical-technological properties consequently.

The aim of this project is to improve the microstructural properties of components manufactured using WAAM. By actively influencing the solidification conditions, fine-grained, quasi-isotropic structures with significantly increased fatigue strength should be achieved. In addition, it is examined which in-process treatment can eliminate any surface defects that may occur. With this previously unused manufacturing strategy using cooperating robots, both subtractive processes and thermal processes are conceivable. Since the expected quality of the structures produced in this way has a significantly higher strength than conventional WAAM structures, a detailed material science analysis is then planned to classify them into relevant notch case concepts.

In the first step, the respective stress-form-numbers and notch-effect-numbers are determined numerically on representative, additively manufactured structures in shipbuilding and these obtained values are validated based on experimental fatigue strength studies. The knowledge gained in this way, in conjunction with further material science investigations, makes it possible to work out the basis for grouping structures manufactured using WAAM into relevant fatigue-catalogs. The samples produced under production conditions are intensively examined. Suitable welding consumables and welding shielding gases are selected and processed with practical welding parameters. An iterative approach, coupled with appropriate measurement technology, is an important prerequisite.

The development of zero-emission technologies plays an important role in complying with the Paris Climate Agreement and reducing net greenhouse gas emissions. The optimal use of energy and resources and the qualification of application-optimized materials are an indispensable lever in this context, which gives rise to the MariSteel research project with a focus on the use of high-performance welding processes in combination with innovative steel materials.

The aim of this project is to pursue CO2-neutral production and to align ourselves with future production conditions towards innovative, flexible production. Another building block is the reduction of the variety of steel types and the development of modern shipbuilding steels, which enable new lightweight construction methods in shipbuilding and contribute to a lower ship mass. A shipbuilding steel that is suitable for the application should have a high level of weldability, be stable in terms of its properties in the heat-affected zone and make optimal use of its potential through full mechanization and automation so that sensible sheet thicknesses can be used.

In this research project, MEYER WERFT is supporting the development of suitable steels for shipbuilding, considering a wide range of application scenarios. At MEYER WERFT, the materials are tested using laser- and laser-hybrid welding processes and the use of increased welding speeds and minimal energy input on structures typical in the shipbuilding environment such as profiles and panels. Our processes will be significantly optimized and a structural design based on steel construction is being developed with the aim of incorporating the changes into the shipbuilding rules in the future.

In respect of the limited resources and the growing volume of waste, sustainable entrepreneurial action and thus the circular economy is an important building block for the future of a company. The EU has set a clear goal for this and is aiming for a climate-neutral and circular economy by 2050.

To meet this challenge, the ReCab project is developing a modular cabin that enables a circular economy in shipbuilding. This includes the selection of suitable materials and a design for disassembly. For this purpose, concepts, materials, components, systems, designs, constructions and circular economy scenarios are developed, tested and evaluated in cooperation with the project participants and suppliers. Material data management enables business models that are analyzed.

A fundamentally new concept of the cabin’s structure and its integration into the ship opens new possibilities for the continued use of the entire cabin and creates great potential in the construction process. The supply systems and control and automation are being developed in energy efficient decentralized units. Any development of the cabin should be accompanied by an improvement in comfort. The feasibility of the concepts and the dismantling and recirculation of the cabin should be proven and tested using demonstrators.

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.

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.

The zero4cruise project aims to make the shipping industry, particularly the cruise sector, more sustainable by developing and integrating innovative fuel cell technologies. Faced with increasing emission regulations and growing environmental awareness among shipping companies and passengers, the industry faces significant challenges. Conventional diesel engine-based propulsion systems are reaching their technical and economic limits. To achieve climate-neutral shipping, the development of alternative energy and propulsion concepts is essential.

The project zero4cruise focuses on advancing PEM fuel cell technology with integrated methanol reforming for use on passenger ships. By utilizing methanol as an energy carrier, these fuel cells aim to reduce or eliminate harmful emissions from onboard energy generation. The project addresses especially retrofitting existing vessels. To meet the high demands for performance, long life, and reliability in maritime applications, large-scale fuel cell systems will be developed and scaled.
A key component of the project is the establishment of a maritime system test stand, where fuel cells will be tested under real-world conditions over extended periods.
Additionally, concepts will be developed and onboard energy systems and networks will be fundamentally redesigned to integrate fuel cell technology as a core energy provider in the multi-megawatt range.
Given the specific requirements of maritime applications, the project involves the improvement of PEM components, particularly the fuel cell stack. By exploring and developing large-scale stacks, zero4cruise aims to unlock the full potential of this technology for the shipping industry and ensures its efficient application.

The project zero4cruise therefore makes a crucial contribution to the future viability of the German maritime industry by supporting the transition to climate-neutral propulsion systems. The project builds on the experiences and developments of a strong consortium, working together to advance the market readiness of maritime fuel cell technology, laying the foundation for a sustainable and environmentally friendly future in shipping.