SciTransfer
ENGINE · Project

Zero-Defect Metal Manufacturing System for Green Marine Engines

manufacturingTestedTRL 6

Imagine building a complex metal part and having it be perfect the very first time, without any wasted material or costly mistakes. This system uses digital twins and smart sensors to catch errors before they happen, like a high-tech spellchecker for factory production. It ensures that new, eco-friendly engines are built right the first time to speed up the transition to green energy.

By the numbers
2 000M EUR/year
Expected increase in turnover
170 million tons
Annual CO2 emissions reduction
The business problem

What needed solving

Metal manufacturing for green engines often suffers from high defect rates and material waste, which increases costs and slows down the transition to sustainable fuels.

The solution

What was built

A first-time-right metal product design system including a computational modelling toolbox, non-destructive diagnostic tools, and a supply-chain data integration solution.

Audience

Who needs this

Marine engine manufacturersPrecision metal casting and forging companiesGreen fuel propulsion system developersIndustrial supply chain managers
Business applications

Who can put this to work

Maritime Engineering
enterprise
Target: Marine engine manufacturer

If you are a marine engine manufacturer dealing with high scrap rates in metal parts — this project developed a first-time-right manufacturing system that reduces waste and ensures technical feasibility for green fuel engines.

Precision Metalworking
SME
Target: Specialized metal component SME

If you are a specialized metal component SME dealing with expensive production defects — this project developed non-destructive diagnostic tools and a computational modelling toolbox that increases competitiveness and reduces manufacturing waste.

Green Energy Infrastructure
any
Target: Eco-fuel engine developer

If you are an eco-fuel engine developer dealing with slow time-to-market for new designs — this project developed a digital design-to-manufacturing system that can help reduce global CO2 emissions by 170 million tons annually.

Frequently asked

Quick answers

How does this impact production costs and pricing?

The system aims to decrease the cost per kilowatt, which is expected to help double the current market share. Based on available project data, this efficiency leads to a projected turnover increase of 2,000M EUR/year.

Is the technology ready for industrial scale?

Yes, the project is demonstrating the system on the marine engine supply-chain and has already developed a Minimum Viable Product (MVP) of the demonstrator.

What are the IP and licensing options?

Based on available project data, the project focuses on transforming innovations into promising business cases, though specific licensing terms are not listed.

How is the system integrated into existing supply chains?

The project developed a data solution specifically for the seamless integration of the entire supply-chain, supported by IoT and AI.

What is the timeline for deployment?

The project period runs from 2022-06-01 to 2025-05-31, with the MVP already achieved in the first 18 months.

Consortium

Who built it

The consortium is heavily industry-driven with a 65% industry ratio, comprising 11 industrial partners including 5 SMEs. This strong commercial presence, balanced by 4 universities and 1 research center (VTT) across 8 European countries, indicates a high focus on commercial viability and practical application rather than pure academic research.

How to reach the team

Contact TEKNOLOGIAN TUTKIMUSKESKUS VTT OY in Finland

Next steps

Talk to the team behind this work.

Contact us to connect with the ENGINE consortium for licensing the zero-defect manufacturing toolbox.

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