Modular RoRo deck

Modular decks for RoRo vessels (non-metallic)

Custom-made hull

Custom made hull for offshore vessel

Fully outfitted and modularised cabin

Multi material lightweight cabin for passenger ships

Panel system (bio-based and other)

Lightweight components for high loads and fire class

Composite block on steel deck

Composite superstructure module on steel deck for multi purpose vessels

Versatile walls

Integration of system for internal walls and superstructure
of cruise ships into shipyard processes

Lightweight rudder flap

Lightweight rudder flap

3D-printed propeller blade

Propeller blades by additive manufacturing

Panel system (truss structure)

Modular light system for less critical internal walls and superstructure

Aluminium composite panels

Lightweight aluminium and composite walls for work boats

High tensile steel decks

Lightweight decks using high tensile steel in cruise ships

Design details (high tensile steel)

Highly loaded structural details from high tensile steel
in passenger and research vessels

Patch repair - composite overlays

Composite overlay to repair and improve metallic and
non-metallic structures

RoRo deck

custom-made hull

cabin system

aluminium panels


versatile walls

rudder flap

propeller blade

truss structures

bio-based panels

steel decks

steel details

patch repair

Lightweight aluminium and composite walls for work boats

State of the Art

In small to medium size workboats single skin extruded aluminium panel are used for the superstructure and the deck houses. The single skin panels are either welded on top of the web frames or are running through the cut-outs in the web frames. When welded on top of the web frames relatively short weld lengths are achieved that might arise strength and fatigue issues if large shear forces are transmitted through the frames. Welding of the single skin panels to form an assembly introduces weld distortions. In addition to visual appearance, the weld distortions can deform the deckhouses of a relatively low stiffness. Thermal and fire insulation of the structures is time consuming as the panels are first insulated in between the stiffeners and secondly on top of the stiffeners.


The development of the design for lightweight and space-efficient extruded sandwich panels for the deckhouses of the small crafts/workboats which include the integration of the new panel system concept into the design and production environment and the development of procedures of joining.


A novel solution is sought in form of double-skin aluminium sandwich panels or composite sandwich panels. A solution based on composite sandwich panels allows less distortions during assembly and flush final surface, thus allowing to decrease the time for insulation. Moreover, the comparison of technical solutions has shown that the weight saving up to 30% can be achieved when using lightweight panels. In order to analyse the practical production issues, a detail design was developed for a smaller structural assembly – a sunroof for a river boat. The main function of the sunroof is not only to provide shelter from the sun and the rain but also to fulfil several technical requirements and provide technical functions, such as a support, charging rails for charging system, support for the LED lights, hatch for engine maintenance, etc. The demonstrator has been produced during the project.


There is a wide application potential especially for numerous small shipyards in Europe which produce a huge number of small vessels, often for local markets.