The state-owned company Navantia has taken a significant step in advanced manufacturing by launching the development of a prototype module for point defense systems on ships at its Puerto Real shipyard. This module is specifically designed for production using large-format 3D printing and new materials. This initiative combines technological innovation, naval defense, and industrial modernization in a single project.
This development is taking place at the Advanced Manufacturing Center (CFA) in Puerto Real , where Navantia is exploring solutions to design and produce lighter, more versatile, and more sustainable structures for naval platforms. The module is designed to be integrated into existing ships and enhance their protection against modern threats such as missiles, aircraft, and unmanned aerial vehicles.
A point defense module designed for ships in service
The new design is geared towards addressing the short-range protection needs of military vessels, what is known in the naval field as point defense systems. These systems act as a second layer of security, intervening once a missile, drone, or aircraft has already breached the first line of defense surrounding the platform.
In this context, Navantia seeks to equip ships with additional capabilities using a modular element that can be installed quickly without major structural modifications. The solution is specifically designed to reinforce the Spanish Navy's assets, including the future Combat Supply Ship (BAC) to be built at the Ferrol shipyard and the Maritime Action Vessels (BAM) planned for Puerto Real.
The module's primary function is to provide structural support for point defense systems located on deck, facilitating their integration and operation in scenarios where threats, especially unmanned vehicles and various types of missiles, have multiplied in recent years. This approach responds to the changing nature of risks at sea and the need to rapidly adapt defensive capabilities.
The prototype under development does not simply reproduce known solutions, but takes advantage of new geometries and configurations made possible by additive manufacturing, with the aim of improving structural behavior, load distribution and compatibility with different defense equipment within the same module.
In addition to its operational role, the project aims to validate a modular design and production methodology that can be reused in other naval programs, both present and future, extending the scope of innovation beyond this first demonstrator.
Plug and play design and portable structure
One of the distinguishing features of this development is its plug-and-play design , intended for installation and use with minimal intervention on the vessel. This allows for faster integration into ships in service, reducing dry dock time and minimizing disruption to daily operations.
The structure has been designed as a self-supporting and portable module , capable of being stored in arsenals and deployed when needed. In this way, the Navy can have units ready for installation as required by operational needs, without having to undertake extensive modifications to each hull.
This modular approach also simplifies logistics and maintenance processes . The fact that each module is a clearly defined unit allows for the use of specific spare parts, standardized inspection protocols, and more precise planning of maintenance and upgrade tasks.
In terms of deployment, the design aims for onboard assembly to be completed quickly and with simplified procedures , resulting in less ship downtime. This speed is especially relevant when platforms need to be adapted to new risk scenarios or technological changes in the defense systems themselves.
The plug and play philosophy also opens the door to integrating different defense equipment or even complementary sensors on the same structural base , configuring module variants depending on the mission or the type of ship where it is installed.
Large-format additive manufacturing and advanced polymers
The prototype is being produced using CEAD's large-format 3D printer, located at the Advanced Manufacturing Center in Puerto Real. This is the first project Navantia has printed at this facility with this machine, which the company considers a milestone both for its own operations and for the development of additive manufacturing in the Spanish shipbuilding industry.
For its development , advanced polymers and additive manufacturing techniques have been selected that allow the materialization of very complex geometries, practically unfeasible or uneconomical through traditional processes such as machining or welding of metal sheets and profiles.
The combination of these materials and the possibilities of large-format 3D printing offers engineers greater freedom when designing , facilitating the optimization of thicknesses, reinforcements and internal shapes to obtain a more efficient structure from a mechanical and weight point of view.
One of the project's most significant results is the estimated 40% weight reduction compared to solutions based on conventional materials and processes. This reduction has a direct impact on fuel consumption, vessel performance, and the ease of handling and assembly of the module itself.
Beyond the prototype, the work in advanced polymers and large-scale additive manufacturing allows Navantia to open new lines of development for other naval components, both in the military field and, potentially, in civil applications that benefit from lightweight structures and customized designs.
The role of the Advanced Manufacturing Center and the Coex network
The project is being developed within the framework of the collaboration between Navantia and the Advanced Manufacturing Center (CFA) of Puerto Real , facilities that bring together technologies such as large format 3D printing, robotics, 3D scanning or the use of drones , and which are located in the La Cabezuela area on land provided by the shipyard itself.
Within the company's structure, the work is led by the Navantia Coex Advanced Manufacturing Center of Excellence , one of the six Coex centers that make up the company's network of excellence. Its mission is to drive the transformation towards new processes and materials, as well as improve product competitiveness through more advanced designs and production technologies.
This center researches and develops initiatives in key technological areas for the naval business , with the aim of cutting costs, shortening manufacturing times and reducing environmental impact, going from the experimentation phase to the industrialization of validated solutions.
In the Bay of Cadiz, Navantia also has the Naval Systems Coex in San Fernando , where work is done in areas such as cybersecurity, the integration of unmanned vehicles (UXV) , advanced communications, multi-domain cloud or hyper-realistic simulation, as well as in European programs linked to holographic capabilities, virtual and augmented reality or autonomous vehicles.
In addition, Puerto Real houses another Coex Green Energies center, focused on marine energies such as floating wind power and green hydrogen, along with applied digitalization projects. This network of centers of excellence forms an ecosystem in which the 3D-printed point defense module serves as a practical example of the commitment to innovation.
Objectives: performance, safety, cost and sustainability
The company places at the center of this project the improvement of the performance of the defense system and, at the same time, the reinforcement of aspects such as security, maintenance, the quality of the final product, the life cycle cost, the versatility of use and the overall sustainability of the solution.
In terms of security, the possibility of integrating point defense systems into modules specifically designed for this purpose allows for optimizing the location and protection of equipment , while also facilitating access for inspection and repair operations under more controlled conditions.
From a maintenance perspective, the use of additive manufacturing and advanced materials opens up options for reproducing parts, adjusting designs, and updating configurations without the need to completely rebuild the structure, which can significantly shorten downtime and reduce spare parts inventories.
In economic terms, the project aims to demonstrate that these processes allow for significant savings in production costs and time , especially when dealing with short series or highly specialized solutions, as is often the case in the European naval military field.
In terms of sustainability, additive manufacturing offers the possibility of optimizing material use and minimizing waste , while the lower weight of the structures theoretically contributes to improving the overall energy consumption of ships and, therefore, their environmental footprint throughout their useful life.
With this 3D printed module prototype, Navantia is consolidating its path in Puerto Real towards the industrialization of lighter, modular and adaptable naval solutions , relying on the network of centers of excellence and the technological capacity of the CFA to respond to European armed forces that demand more flexible defense systems, faster to integrate and aligned with the new challenges of the maritime environment.
