ShearWater aquatic drone, manufactured with fiberglass-reinforced recycled PETG, demonstrates precision 3D printing capabilities, sustainability focus and design innovation for maritime and heavy-duty applications. Royal3D (Rotterdam, Netherlands) highlights its large-scale additive manufacturing (LSAM) capabilities through the ShearWater aquatic drone, a recent project partly subsidized by the ER CrossRoads program meant to redefine surveillance, data gathering and risk reduction in maritime environments.

According to Royal3D, the autonomous aquatic drone — integrating maritime AI-driven technology and 3D printing — could be used as a prototype for startups developing their own autonomous system. The ShearWater drone was printed via Royal3D’s ABB Robotic Arm 3D printer and a CEAD (Delft, Netherlands) LFAM printer using recycled PETG reinforced with 19% short glass fibers. Not only does this achieve light weight and impact resistance, but Royal3D can additionally recycle the drone’s 3D printed hull.

At the heart of the ShearWater’s design is Royal3D’s IP knowledge, which enables precise control over layer adhesion during the 3D printing process using InfraRed cameras coupled with the company’s AM techniques. 

“What sets Royal3D apart is our ability to adapt advanced 3D printing technologies for industries like maritime and heavy-duty manufacturing, where the demands on strength and durability are unparalleled,” says Fulko Roos, founder of Royal3D and Royal Roos. “At the same time, our expertise in urban design and architectural applications continues to deliver innovative solutions across diverse sectors.”

Royal3D has more than 10 years of industry experience. The company specializes in producing large-scale, high-performance components such as transport cradles, structural elements and customized industrial parts, owning what it says are two of the largest printers in Europe. Additionally, Royal3D is committed to sustainability, using recycled and recyclable materials to reduce environmental impact and promote a more sustainable approach to manufacturing.

While Royal3D remains a trusted partner for interior and exterior design and urban applications, the ShearWater drone exemplifies the company’s renewed focus on maritime and industrial manufacturing. It continues to expand its capacity for large-scale printing in order to reshape how industries approach production, material efficiency and design capabilities. 

» Publication Date: 30/04/2025

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