Sangiorgio Marine redefines yacht superstructures production with LFAM

Sangiorgio Marine chose to collaborate with Caracol to restyle the hard-top of the Wally Power 64 “Tenderissimo” yacht, leveraging Heron AM additive production capabilities.

As part of the restyling of the Wally Power 64 “Tenderissimo” yacht, Sangiorgio Marine aimed to enhance performance, aesthetics, and production efficiency. To achieve these goals, the team of designer, Giuseppe Martines, and structural engineer, Paolo Dassi, conducted an in-depth study to develop a superstructure that preserves the yacht’s signature design while incorporating advanced functionality.

The new hard-top design features a roof supported by “chimney” side windows that improve airflow and ventilation. Its structure reflects the company’s expertise in merging elegance with cutting-edge materials and manufacturing techniques.

Bringing Innovation to Life with Additive Manufacturing processes
To realize their vision, Sangiorgio Marine leveraged Caracol’s robotic additive manufacturing technology, using the Heron AM system for quality, sustainability, and innovation.

The Hard-top was composed of two lateral sections and one upper, easily assembled into the final structure. The following data reflects the total, key production details:

• System: Heron 300
• Extruder: High Accuracy (HA)
• Nozzle Size: 5 mm
• Material: ABS + 20% CF and ASA + 20% Glass Fiber
• Printing Time: 110 hours
• Weight: 130 kg
• Dimensions: 4000 x 2000 x 1700 mm
• Post-Processing: Hand sanding and painting

Key advantages
By eliminating traditional tooling and lamination steps, Heron AM significantly enhances manufacturing agility and sustainability. The adoption of Caracol’s additive technology delivered remarkable benefits:

• Waste Reduction: 70%
• Cost Reduction: 30%
• Weight Reduction: 15%
• Lead Time Optimization: 60%

The impact of LFAM on the marine industry
The custom superstructures developed with Heron AM for the Wally Power 64 yacht represent a major leap forward in marine additive manufacturing.

By integrating large format additive manufacturing into this restyling project, Sangiorgio Marine affirms its commitment to pioneering innovative marine manufacturing techniques, setting a new standard in the yacht manufacturing industry.

This project showcases how advanced AM technology can effectively tackle complex production challenges while optimizing cost efficiency, production time, and sustainability. Beyond meeting strict functional and aesthetic requirements, this approach paves the way for future innovations in yacht construction.

Ph. Yacht Photos – Sangiorgio Marine

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