636 Miles with a 3D Printer

Running the Newport-Bermuda Race is a test of preparation and endurance. In June 2026, we decided to add an additional parameter to S/V Osprey's race program: we bolted a Prusa Core One L 3D printer directly to the navigation desk, wired it to our 24V lithium battery bank, and set off to see how additive manufacturing handles 636 miles of ocean swelling.

The goal was not to print novelties. We wanted to test the physical limitations of printing under constant 15 to 25-degree heel angles, checking how acceleration forces and boat vibration affect layer adhesion and print tolerances.

Vibration Isolation & Power Integration

To isolate the printer from the pounding of the hull, we engineered a custom baseplate fitted with rubber vibration-dampening mounts. Power was clean: the printer was wired via a dedicated 24V-to-24V DC-DC stabilizer, bypassing inefficient AC inverters and drawing a steady 90W during chamber heating cycles.

For the first 200 miles, the printer ran continuously, extruding a series of test coupons in marine-grade ASA. The results were surprising: despite the rolling and pounding, the fully enclosed heated chamber kept the ambient air at a steady 55°C, ensuring no warping occurred at the edges.

The Emergency Gimbal Print

On day three, the race threw a real test our way. The custom marine mount holding our primary satellite transceiver sheared off during a sudden gybe. Without the transceiver, we would lose real-time weather files and safety tracking.

We measured the mounting rails with calipers, modeled a reinforced replacement bracket in CAD, and sliced it with settings optimized for stiffness. Four hours later, we had a solid Carbon-Fiber Nylon (PA-CF) bracket ready for installation.

The bracket held for the remaining 300 miles of the race, enduring constant salt spray and structural load. Additive manufacturing at sea is no longer a concept; it is an active safety tool.