01
Additive Build
Build the optimised geometry directly, layer by layer, with no casting mould.
- ✓Wire-Arc (WAAM) & laser-based additive
- ✓Hybrid processes & CAM toolpaths
- ✓Geometries casting cannot produce
Manufacturing & Remanufacturing · From Carbon To Silicon, and beyond
Building the Design, Layer by Layer.
No mould, no casting - the optimised geometry is built directly by robots and finished with digital precision.
Geometries casting cannot reach, up to 80% less material waste, delivery in 4-6 weeks instead of 12-16 - and the world's first fully additively manufactured marine propeller, certified.
Additive buildLayer by layer
Our Process
How We Build.
A validated digital model arrives from design and is built directly - no casting mould. Computer-aided manufacturing generates the robot toolpaths, additive cells build the geometry, robots finish it, and Edge AI and metrology verify it - with remanufacturing keeping it in service. Four stages, left to right.
Under the hood: CAM toolpath generation; Wire-Arc Additive Manufacturing (WAAM); laser-based additive manufacturing; robotic post-processing; multiple Mencast robotic cells running in parallel.
The four stages, in order
02
Robotic Finishing
Finish the built part to specification with consistent, repeatable robotic precision.
- ✓Robotic grinding & surface refinement
- ✓Geometric correction to design intent
- ✓Repeatable finish, less physical strain
03
Edge AI Quality
Verify weld and build quality in real time, during the build - not only after.
- ✓Meltpool camera, acoustic & thermal sensing
- ✓Trained ML on an on-machine Edge AI device
- ✓Live defect detection & predictive maintenance
04
Metrology & Remanufacturing
Verify against design, record it, and extend the part's life.
- ✓Precision metrology & digital twin
- ✓Digital propeller passports for traceability
- ✓Remanufacturing of worn components
Build•
Finish•
Verify•
Sustain
Connected by a single digital thread.
Proven, Not Promised
The World's First Certified AM Marine Propeller.
Mencast developed the world's first fully additively manufactured marine propeller - certified by the American Bureau of Shipping (ABS) and Lloyd's Register.
12-16 weeks→4-6 weeks
typical delivery, versus traditional casting
Casting baseline→Up to 80% less
material waste, versus casting
- ✓Stronger, lighter and more durable components.
- ✓Rapid prototyping and faster validation.
- ✓Multiple design options - not locked to a single casting mould.
- ✓Complex geometries casting cannot produce.
See the certified propeller and its certificate on our Verification & Certification page →
Why It Matters
Less Waste, More Life.
Traditional Casting
Mould-bound and wasteful.
Fixed mould geometries, heavy material waste, manual finishing and inspection - and when a part wears, it is replaced.
Digital Additive
Built to need, then renewed.
Build only the material required, finish and inspect robotically, verify in-process with Edge AI - and remanufacture worn parts rather than scrap them.
Every stage is measured, recorded and reusable - waste falls and asset life extends.
The Value Created
What Manufacturing & Remanufacturing Delivers.
Up to 80% less waste
Shorter lead times
Geometries beyond casting
Certified quality
Full digital traceability
Multiple robotic additive cells run in parallel - production capacity, not a single prototype rig.
45years of marine propulsion engineering
200engineers and technicians
10,000+propulsion solutions delivered
1-stopdesigner, manufacturer and repairer in Singapore
A certified part with a complete digital record is ready for service - and ready to be renewed when it returns.