With rising demands for energy efficiency and reduced emissions, the shipbuilding industry is increasingly turning to lightweight and corrosion‑resistant composite materials. The BIGBOND research project explores how fibre‑reinforced composites can be used on a larger scale in ship structures and how reliable bonding technology can help unlock their full potential.

The focus of BIGBOND lies on developing new design principles, standardised adhesive joints and scalable manufacturing processes that allow composite components to be integrated safely and efficiently into ship structures. In addition, BIGBOND investigates concepts for reusable and circular components, ensuring that sustainability is considered across the entire lifecycle.

A key aspect of the project is the further standardisation of bonding processes, which is essential for simplifying certification processes and enabling broader industrial adoption. Over the course of the project, all developed solutions will be validated using a demonstrator to ensure practical relevance and transferability into real shipbuilding applications.

Bonding plays a crucial role in making lightweight composite materials viable for maritime use. Their low weight and long service life can make an important contribution to reducing emissions. At the same time, recycling remains a challenge that the project addresses directly. Through life‑cycle assessments, continuous research on composite materials and design approaches that allow reversible and clean separation of components, BIGBOND aims to support a more sustainable end‑of‑life strategy for these materials.

With this comprehensive approach, the project contributes to advancing lightweight construction, alternative joining methods and environmentally responsible production to support the climate‑friendly transformation of the maritime sector.

We would like to thank the Federal Ministry for Economic Affairs and Energy (BMWE) and the Projektträger Jülich (PtJ) for their funding and the coordination of this innovative project.

Project partners: Center of Maritime Technologies (CMT) gGmbH, Institut für Leichtbau und Kunststofftechnik ILK - Technische Universität Dresden, Fraunhofer IGP, Tamsen Maritim GmbH

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.

We would like to thank the Federal Ministry for Economic Affairs and Energy (BMWE) and the Projektträger Jülich (PtJ) for their funding and the coordination of this innovative project.

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.

We would like to thank the Federal Ministry for Economic Affairs and Energy (BMWE) and the Projektträger Jülich (PtJ) for their funding and the coordination of this innovative project.

The transition to climate-friendly, hydrogen-based energy carriers presents the shipping industry with new challenges regarding material durability, safety, and long-term operational reliability. Within the KoSyShip research project, we are investigating the corrosion behavior of methanol and ammonia together with our partners and developing innovative solutions for their safe use on board ships.

Methanol and ammonia are considered promising synthetic fuels that play a central role in the decarbonization of shipping. However, depending on their purity, handling conditions, and mechanical stress, both substances can cause complex corrosion effects on conventional steels, alternative metal alloys, and protective coatings. A sound understanding of these mechanisms is therefore essential for the development and operation of future fuel systems.

In the KoSyShip project, we are investigating in detail how methanol and ammonia affect various materials under real-world operating conditions. Through practical experiments, we aim to understand how these fuels influence corrosion and the long-term stability of components. The insights gained will help us develop improved design principles and manufacturing methods to ensure that future fuel systems for methanol and ammonia are durable and safe.

We thank the Federal Ministry for Economic Affairs and Energy (BMWE) and the Projektträger Jülich (PtJ) for funding and coordinating this innovative project.

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.

We would like to thank the Federal Ministry for Economic Affairs and Energy (BMWE) and the Projektträger Jülich (PtJ) for their funding and the coordination of this innovative project.

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.

We would like to thank the Federal Ministry for Economic Affairs and Energy (BMWE) and the Projektträger Jülich (PtJ) for their funding and the coordination of this innovative project.

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.

We would like to thank the Federal Ministry for Economic Affairs and Energy (BMWE) and the Projektträger Jülich (PtJ) for their funding and the coordination of this innovative project.