Flexible Customization of Large-Scale Yacht Components through a Design- Driven Approach

The yacht industry’s reliance on traditional mold-based composite manufacturing presents significant challenges in terms of design flexibility, cost, and environmental sustainability, particularly for customized or limited-series components. This paper presents the results of the NEMO and CYClaDEs research projects, which explore a zero-tools flexible approach that integrates large-scale composite- reinforced additive manufacturing (AM) with computational design. A comparative case study of an integrated yacht component was conducted, benchmarking the proposed method against the conventional processes. The findings reveal significant improvements across key manufacturing metrics, prompting a critical discussion on the broader implications, including the redefinition of the designer’s role in a digital workflow, the enhancement of product value through deep customization, and a clear pathway towards more circular and scalable production models. This research demonstrates a viable, design-driven pathway for the Made in Italy nautical sector to achieve greater flexibility and circularity, aligning the demand for high-level customization with sustainable and digital innovation.