1,200 mm Patrol Vessel Propeller Reproduced from a Damaged Existing Component
A damaged physical propeller became the engineering reference for producing one 1,200 mm replacement in ASTM B148 C95800 nickel aluminium bronze. The project combined 3D scanning, CAD reconstruction, casting simulation, a 26-section 3D-printed sand mould system, casting, finishing and dynamic balancing before the completed propeller entered operational service.
Finished replacement propeller documented in Using 3D Sand Printing Technology in Part Replacement (2017).
Project at a Glance
Component
Five-Blade Marine Propeller
Application
Patrol Vessel Replacement
Finished Diameter
1,200 mm
Finished Weight
650 kg
Material
ASTM B148 C95800 Nickel Aluminium Bronze
Mould System
26 Printed Sand Sections
Starting Reference
Damaged Physical Propeller
Outcome
Entered Operational Service
Selected project information is presented without the customer identity, vessel designation, drawings or confidential technical data.
The Replacement Challenge
A Damaged Reference with No Original Pattern
A damaged physical propeller was the available starting reference, and the original pattern tooling was not available. The replacement geometry therefore had to be reconstructed from the existing component.
Damaged areas could not simply be copied into the manufacturing model. The project required manufacturable geometry and a mould system for a large C95800 casting, followed by the finishing, hub work and dynamic balancing needed before operational use.
Engineering Reconstruction
From Damaged Reference to Manufacturing Geometry
3D scanning records physical geometry as measured. Engineering review then separates usable reference geometry from damaged or degraded areas before CAD reconstruction creates a manufacturable definition.
Hub and shaft-connection relationships, blade-to-hub relationships, principal dimensions and installation interfaces were reviewed together with the casting and finishing requirements.
The damaged condition was not copied directly. Usable reference geometry was separated from areas requiring reconstruction and engineering review.
What Was Reconstructed and What Had to Be Preserved
Reconstructed or reviewed
—Damaged or degraded blade geometry
—Surface continuity where reference data remained usable
—Manufacturable CAD geometry
—Casting and finishing allowances
—Geometry required for mould production
Preserved as engineering references
—Hub and shaft-connection relationships
—Blade-to-hub relationships
—Usable blade geometry from the existing component
—Principal component dimensions
—Interfaces required for the existing installation
Casting Engineering
Casting Simulation Before Mould Production
Casting simulation was used to review the proposed casting system before mould production, including filling behaviour, solidification sequence, proposed gating and feeding arrangements, and areas requiring attention during process planning.
The simulation supported review of the proposed casting process before the mould sections were printed. It did not guarantee a defect-free casting.
Mould Production
Why the Mould Was Divided into 26 Sections
The large and complex sand mould geometry was divided so it could be produced within the available print envelope. The organised sections were binder-jet printed and assembled into one complete mould package before pouring.
Mould-printing record: 26 sand mould sections printed in five days. This is the printing time for the mould sections, not the total propeller manufacturing or delivery time.
The 26 pieces were printed sand mould sections. The metal propeller was not manufactured as 26 separate pieces.
Exploded digital view of the separate mould sections. Source: published 2017 project record.
Engineering-to-Manufacturing Workflow
From Physical Reference to Operational Use
01
Damaged Component Assessment
Review the physical propeller and identify usable reference geometry.
02
3D Scanning
Capture the existing propeller geometry as measured digital data.
03
CAD Reconstruction
Reconstruct manufacturable geometry without copying damaged areas directly.
04
Casting Engineering
Prepare the component and casting-system geometry for mould production.
05
Casting Simulation
Review the proposed filling, feeding and solidification behaviour before printing.
06
26-Part Sand Mould Production
Binder-jet print the separate sand mould sections directly from prepared digital data.
07
Mould Assembly
Assemble the 26 printed sections into the complete mould package.
08
C95800 Casting
Cast the propeller in ASTM B148 C95800 nickel aluminium bronze.
09
Finishing and Hub Work
Complete the required finishing and hub-related work.
10
Dynamic Balancing
Perform dynamic balancing before operational use.
11
Operational Use
Place the completed replacement propeller into service.
Project Evidence Gallery
Published Mould and Finished-Component Evidence
These figures are from the matching 2017 technical record. No confidently attributable damaged-reference, scan, CAD or simulation image is available for this page.
Exploded digital view of the 26 separate sand mould sections prepared for the propeller mould.Examples of the binder-jet printed sand mould sections before assembly.The printed sections assembled into one complete mould package before pouring.The finished five-blade C95800 replacement propeller documented in the 2017 technical record.
Verified Project Outcome
One five-blade replacement marine propeller was produced.
The finished diameter was 1,200 mm and the finished weight was 650 kg.
ASTM B148 C95800 nickel aluminium bronze was used.
The damaged physical propeller was used as the starting engineering reference.
Casting simulation was included in the engineering workflow.
The mould system comprised 26 printed sand sections.
Finishing and dynamic balancing were completed.
The completed propeller entered operational service.
Detailed historical inspection, balancing and operational records from this earlier project are not presented on this page.
Engineering Boundary
Every marine replacement project is reviewed individually. Geometry, alloy, casting process, inspection requirements, balancing scope and project timing depend on the condition of the reference component, the available engineering information and the vessel requirements. Results from this project should not be treated as a standard lead-time or performance guarantee for other propellers.
Project-Specific FAQ
Can a damaged marine propeller be used for reverse engineering?
It can provide useful measured geometry and interface information, subject to an engineering review of what remains usable and what must be reconstructed.
Does 3D scanning copy the damaged geometry directly?
No. Scanning records the physical condition as measured. Damage and degradation are separated from usable reference geometry during CAD reconstruction and engineering review.
What did 3D sand printing produce in this project?
Binder-jet 3D sand printing produced the separate sand mould sections. It did not print the metal propeller.
Why was the sand mould divided into 26 sections?
Sectioning allowed the large, complex mould geometry to be produced within the available print envelope and then assembled into one complete mould package.
Was the propeller cast as one component?
Yes. The 26 pieces were sand mould sections; the C95800 metal propeller was cast as one component in the assembled mould.
Was casting simulation used?
Yes. Simulation supported review of the proposed filling, feeding and solidification behaviour before mould production. It was an engineering review tool, not a guarantee of a defect-free casting.
Was the completed propeller dynamically balanced?
Yes. Dynamic balancing was performed before the completed propeller entered operational service. Detailed historical balancing records are not presented here.
Does every marine propeller project follow the same route?
No. The route depends on the condition of the reference, available engineering data, alloy, inspection and balancing scope, installation requirements and project timing.
Need to Reproduce a Damaged or Obsolete Marine Propeller?
Provide available photographs, principal dimensions, material information, scan or CAD data if available, required quantity, finishing scope, inspection requirements and operational context for an initial engineering review.
Speed 3D Mold Co., Ltd. is listed by ExOne as a sales representative in Thailand, supporting local coordination for industrial sand 3D-printing solutions.
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