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The Role of 3D Printing in Ocean Conservation

Published on July 24, 2024 by Isaac B.

The health of our oceans is critical to the well-being of our planet, yet they face increasingly significant challenges from various sources in this modern age: climate change-induced warming and acidification, plastic pollution choking marine life, habitat destruction, rising sea levels, and unsustainable fishing practices. These challenges collectively undermine marine ecosystems, endangering species and disrupting coastal economies that rely on healthy oceans. Immediate solutions are needed to mitigate these impacts and safeguard our oceanic resources for future generations.

And that goes without mentioning the fact that many of these problems are human-made – for example, the destruction of habitats due to activities such as coastal development and bottom trawling, as well as the depletion of fish populations from overfishing.  This despite the fact that humans are also victims as the threat of rising sea levels, a consequence of climate change and polar ice melting, is also a significant concern for coastal communities. What is clear in any case is that pervasive issues threaten marine biodiversity and impact coastal communities worldwide. Luckily, amidst these challenges, innovative technologies like 3D printing are emerging as useful tools in the fight for ocean conservation.

(Photo Credits: BBC)

3D printing offers unique solutions for tackling these ocean sustainability challenges. Unlike traditional manufacturing methods, which often produce substantial waste, 3D printing allows for precise and customized production. This is what is driving interest in the use of additive manufacturing as well as other 3D technologies, such as 3D scanning, in the fight against environmental issues, including in the oceans.

By turning to additive manufacturing, not only are different groups finding creative ways to fight against challenges facing ocean conservation, but they are able to do it in a way that is more eco-friendly. To gain deeper insights into this transformative technology, we spoke to experts at the forefront of several of these pioneering projects. Their firsthand accounts shed light on the processes, objectives, and real-world impact of 3D printing in revolutionizing ocean conservation.

Coral Reef Restoration

Coral reefs are among the most biodiverse ecosystems on Earth, yet they are increasingly threatened by climate change, pollution, and physical damage. The integration of 3D printing in coral reef restoration represents a promising approach to mitigate these threats. Organizations like D-Shape and Archireef are at the forefront, utilizing 3D printing to create artificial reef structures that mimic natural coral formations. These structures provide essential habitat for marine organisms and facilitate coral larval settlement, promoting reef recovery and resilience. Clearly showing that additive manufacturing has a clear role to play when it comes to mitigating the threat faced by coral reefs, 14% of which have disappeared since 2001.

(Photo Credits: Kind Designs)

Indeed, creating new reefs is a hugely important mission. The destruction of a reef means the death of an entire ecosystem, resulting in extinction for certain animals, with long-reaching consequences for the planet, including setbacks for medical care. However, recreation can be hard as the artificial reefs need to be as appealing as the natural versions. This is where additive manufacturing shows its strength.

The flexibility and geometric complexity available through additive manufacturing make it possible to create more interesting and dynamic structures than would be possible with traditional methods. Not to mention, considering that the destruction of coral reefs is an environmental issue, many are drawn to 3D printing as it allows the creation of the reefs with natural materials like terracotta with less waste. These are core reasons driving the adoption of 3D printing in the field.

And the recreation of coral reefs with additive manufacturing can also serve other purposes. For example, Miami-based tech company Kind Designs has also turned to 3D printing in the restoration of coral reefs. What distinguishes them, however, is that the company has innovatively applied the technology to tackle multiple environmental challenges simultaneously.

Recognizing the dual threats of coastal erosion and declining marine biodiversity, Kind Designs has developed a groundbreaking solution: 3D printed Living Seawalls. Unlike traditional concrete seawalls that often exacerbate environmental degradation, Kind Designs’ Living Seawalls serve as robust barriers against rising sea levels while functioning as vibrant marine ecosystems akin to coral reefs. Designed to mimic natural marine habitats like mangrove roots, these seawalls provide shelter and breeding grounds for diverse aquatic species, contributing to ecological resilience.

Kind Designs’ 3D printed ‘Living Seawalls’ (Photo Credits: Kind Designs)

Anya Freeman, Founder and CEO of Kind Designs, spoke on the advantages of these walls, stating, “These Living Seawalls are structurally identical to traditional seawalls: same PSI, same reinforcement, and same installation method. However, through material composition and biomimicry design principles, these walls also function as marine habitats. They have large caves that protect sea life from predators, and their rugosity and texture are ideal for smaller organisms to attach to and thrive even during extreme weather events.”

Another distinctive feature of these walls is their construction with a proprietary material blend that is free from metals and chloride. This design ensures that no harmful chemicals leach into the ocean, a stark contrast to traditional seawalls that degrade over time, posing environmental risks and contributing to habitat loss. “Our materials have been used in successful artificial reef projects and even reservoirs for drinking water. Although we just started installing them, we have historical data on the material’s use in other marine and environmental applications going back many years,” confirmed Freeman.

Again, here we see that 3D printing was chosen not just for its more eco-friendly nature but also for its ability to make more dynamic structures. A large strength of these sea walls is in their shape and that is much more possible with extrusion 3D printing. Not to mention, it is often lower cost than other methods. Once again showing the importance of 3D printing in ocean conservation.

In addition, it’s not just 3D printing that is helping corals, but other 3D technologies have their role to play. 3D scanning technology further enhances marine conservation efforts by providing detailed insights into underwater ecosystems. Artec 3D‘s Spider 3D scanner, for instance, is revolutionizing the way scientists study coral reefs. By creating precise 3D models of coral structures, researchers can monitor changes in growth patterns, morphology, and overall health with unprecedented accuracy.

The Spider 3D scanner by Artec 3D (Photo Credits: Artec 3D)

“Using blue-light technology, the high-resolution Artec Spider ensures the best possible quality of scans. It is perfect for capturing small objects or intricate details with steadfast accuracy and brilliant color,” explained Sergey Sukhovey, Artec 3D’s Founder & Chief Experience Officer. This capability is invaluable for quantifying the effects of environmental stressors like temperature change and pollution on coral resilience.

The Spider’s noninvasive scanning approach minimizes disturbance to marine ecosystems, as Sukhovey highlighted when speaking on methodologies like the ‘toothpicks & needles’ approach. This approach allows for comprehensive scanning of entire corals without repositioning, further safeguarding their fragile structures. Ultimately, this allows researchers to quantify changes over time by measuring coral dimensions, providing critical insights for sustainable management and protection of coral reefs.

Sukhovey further notes that “The Spider’s ability to facilitate this research at Giessen University is critical to ocean sustainability since, under relentless environmental pressures such as climate change, overfishing, and pollution, more than 50% of the world’s coral reefs have died off since the 1950s. Of those remaining, up to 90% may not survive the next 100 years. If all the corals die, then so will the fish – and extinction means forever.”

Ocean Debris Removal and Recycling

Alongside the destruction of reefs, the pervasive presence of plastic debris in oceans poses another major threat to marine life and ecosystems. With more than 16 million tons of plastic and other ocean waste entering marine ecosystems annually, the need to protect our seas has never been more pressing.

Fortunately, startups like Fishy Filaments are tackling this issue, transforming discarded fishing nets into high-quality nylon filaments and closing the loop on plastic waste while supporting sustainable manufacturing practices. Fishing nets, often made from nylon monofilaments, contribute significantly to global fishing gear and pose environmental challenges due to their persistence and impact.

(Photo Credits: Olive Ridley Project)

“The UN FAO has identified the lack of waste management infrastructure as a causal factor in the global issues around fishing net disposal and loss,” Fishy Filaments founder Ian Falconer states. Recognizing this issue, the company aims to make a significant impact on carbon emissions across the nation through the development and operation of plastics recycling technologies.

“What this means in practical terms is that we’re not really an AM company. We’re a recycling infrastructure developer with a technology set that can operate at a hyper-local scale and produce a specific material. That scale aligns well with AM, and the material, Nylon 6, has been part of the 3D printing world since the very early days.”

Fishy Filaments provides a critical service by making recycling economically viable at the harbor level. They aim to “make good fishing gear management pay well,” which helps local communities benefit from recycling efforts. Their recycled nylon material, OrCA, is designed to cross the boundaries of small and mesoscale manufacturing technologies. By doing so, they reduce the environmental impact of plastic waste and support sustainable practices in both traditional and additive manufacturing industries.

Fishy Filaments’ OrCA filament. (Photo Credits: Fishy Filaments)

Falconer continues, “We’d be providing what is known as a scale-out technology. We aim to replace the monolithic, centralized, carbon-inefficient plastic recycling plants that capture just 15-20% of the nylon monofilament nets used each year around the world. By shifting the economic balance towards the fishing communities, the goal is to make recycling nets pay well at the harbor level. By making good fishing gear management pay, healthy communities can afford to own and run that infrastructure for their benefit.”

This approach not only addresses the environmental impact of abandoned, discarded, or lost fishing gear, but also fosters economic resilience within coastal communities. “We’re more of an enabler for others, giving them access to materials they couldn’t otherwise develop or provide on their own,” Falconer explained.

Highlighting an example of how their filament is used, Falconer illustrated a collaboration involving Mutiny Shaving, a startup committed to reducing plastic waste from disposable razors. “Single-use plastics are a scourge in the ocean. We provide Mutiny Shaving with a route to do the opposite of their competitors. Their customers can contribute to keeping the ocean clean, one razor at a time, where their big-name competitors are a source of marine litter,” highlighted Falconer.

Falconer also expressed that the company collaborates extensively with universities, research institutions, and governmental agencies, depending on their interests, to advance ocean conservation and recycling technologies. These partnerships contribute to policy discussions and innovations that promote sustainable practices in the fishing industry and beyond.

(Photo Credits: Fishy Filaments)

Looking forward, Fishy Filaments aims to upscale its impact by expanding its recycling technologies and product offerings. “Our mission is global carbon reduction through resource-efficient manufacturing. As a growing manufacturing technology, AM is a key customer segment and one that is uniquely placed to switch between materials with relative ease. We need to understand and enable AM users to make pro-environmental choices from a design level. We will be stuck supplying a Victorian model of high-waste mass production and poor end-product disposal if we don’t. Overall, as a company, we want to make ocean-positive choices available and visible.”

Sustainable Seafood Innovations Through 3D Printing

But coral restoration and recycling are not the only ways we are seeing the benefits of 3D printing in ocean conservation. It is also being used to address one of the biggest problems facing oceans: overfishing.

It is increasingly clear that the demand for seafood is straining marine resources, prompting the exploration of alternative protein sources and sustainable food practices. The World Bank reports that over 90% of fish stocks are overfished, with rising consumption driving the populations of most in-demand fish below 50% in the last several decades. 3D printing technology is facilitating innovation in this field by enabling the production of plant-based seafood alternatives that replicate the texture and nutritional profile of conventional seafood products.

Revo Foods’ ‘The Filet’ (Photo Credits: Revo Foods)

Companies like Revo Foods are advancing the development of plant-based fish fillets and seafood substitutes using 3D printing. Using ingredients such as plant proteins and natural flavors, these products offer consumers sustainable and ethical alternatives to traditional seafood consumption, contributing to ocean conservation efforts. The scalability of 3D printing technology allows mass production of these products, reducing reliance on fish stocks and alleviating pressure on marine ecosystems. “Our mission is to make food production more flexible and sustainable by developing modern food processing technologies,” the company stated.

One of Revo Foods’ flagship products is their plant-based Filet alternative, which is primarily made from mycoprotein. This innovative ingredient, described as a “fermented superfood,” boasts a complete amino acid profile, making it a sustainable and nutritious protein source. This alternative promises a sustainable protein alternative that mimics the texture and taste of fish filets without the environmental impact. Robin Simsa, CEO of Revo Foods, highlighted the benefits of the substitute, explaining, “Mycoprotein has a doubling time of only 5 hours, so it is truly a super-protein for a sustainable food supply.”

Various 3D printed fish recipes by Revo Foods, including salmon, tuna, and their Filet recipe. (Photo Credits: Revo Foods)

Additionally, Simsa emphasized the advantages of 3D food structuring, particularly for creating complex, next-level products with new functionalities, stating, “3D Food Structuring has a main advantage for complex, next-level products with new functionalities. For example, by combining two different ingredients in any shape or structure we want, we can create a completely new mouth-feel and fibrousness that consumers have not tasted before. This is really exciting because only with better products can we convince consumers to give these products a chance.”  This capability allows them to produce plant-based seafood with a texture and taste that closely mimics traditional fish, encouraging consumers to embrace sustainable food options.

Within just a few months, Revo Foods aims to demonstrate the scalability of its technology with its first production facility, set to be operational in August 2024. They are preparing to launch their advanced product, the new Filet 2.0, to the market shortly after. Besides, they are not the only ones in the field showing the huge potential for additive manufacturing in helping to address issues related to overfishing by providing alternatives to customers.

The Future of Ocean Conservation: 3D Printing and Collaboration

Looking ahead, the integration of emerging technologies like 3D printing, coupled with enhanced partnerships across an extensive range of sectors, holds immense promise for advancing ocean sustainability goals. The efforts by companies such as Kind Designs, Artec, Fishy Filaments, and Revo Foods (among many others) demonstrate the potential for 3D printing to address various environmental challenges, ranging from habitat restoration and plastic waste recycling to sustainable food production. These technologies not only provide immediate solutions but also pave the way for long-term strategies in ocean conservation.

By continuing to develop and implement these cutting-edge solutions, 3D printing can drive significant progress in protecting and restoring our oceans, ensuring a healthier and more resilient future for marine ecosystems and the communities that depend on them. As collaboration and technological innovation expand, the potential for impactful, sustainable ocean management becomes increasingly attainable.

What do you think of the various roles and applications of 3D printing in ocean conservation? Let us know in a comment below or on our LinkedIn, Facebook, and Twitter pages! Don’t forget to sign up for our free weekly newsletter here for the latest 3D printing news straight to your inbox! You can also find all our videos on our YouTube channel.

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