Over the past twelve months, Digital Dry Dock has been using its 3D laser scanning technology to assist with dredging vessels refit and repair in multiple locations across the UK. 

Our technology makes maintenance and safety inspections of vessels much easier and quicker than using traditional hand-measuring techniques. 

In this blog, we share the second of two projects with you in which we saved our clients time and expense by using our 3D scanning technology on their dredging vessels. 

Project 2: Arco Dart 

Later in the year, Digital Dry Dock had the opportunity to assist Heidelberg Materials UK with their vessel, the Arco Dart, at Avonmouth Docks in Bristol. This project focused on reverse engineering key vessel components, including the loading tower, reject chute, and dredging ‘slipper’, to support the design and fabrication of new replacement parts.

Phase 1: Scanning of the loading tower and reject chute 

To ensure the accurate replication of these essential components, we conducted a high-resolution 3D scan using the Leica RTC360 3D Laser Scanner. The scanning process captured an as-built digital model, which was then used to create a 3D surface model and digitise the original fabrication drawings.

This data enabled precise reverse engineering, ensuring the new components would be a perfect fit when installed on the vessel.

Phase 2: 3D Scanning of Californian Draghead dredging ‘slipper’

The Arco Dart’s Californian Draghead dredging ‘slipper’ also required replacement. Using the same Leica RTC360 3D Laser Scanner, we captured an accurate surface model.

With these 3D models and 2D sectional drawings, Heidelberg Materials UK had the precise data needed to manufacture a new dredging ‘slipper’ with confidence.

Final result

By leveraging our 3D scanning and CAD expertise, we helped Heidelberg Materials UK modernise critical components on the Arco Dart without relying on outdated or incomplete original fabrication drawings. This ensured a cost-effective, precise, and efficient approach to vessel maintenance and upgrades. We were able to complete the entire project, with one day spent on site and CAD drawings delivered within one week. 

Get in touch 

These projects demonstrate how Digital Dry Dock’s advanced 3D scanning technology can streamline maintenance, reduce downtime, and improve asset management for dredging vessels across the UK.

For inquiries about similar projects, contact us at Digital Dry Dock. 

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Servicing UK Dredgers– 3D Scanning, Ultrasonic

Over the past twelve months, Digital Dry Dock has been using its 3D laser scanning technology to assist with dredging vessels refit and repair in multiple locations across the UK. 

Our technology makes maintenance and safety inspections of vessels much easier and quicker than using traditional hand-measuring techniques. 

In this blog, we share the first of two projects with you in which we saved our clients time and expense by using our 3D scanning technology on their dredging vessels. 

Project 1: A.I Avocet

Last year, Digital Dry Dock had the privilege of working with Aggregate Industries on their vessel, the A.I. Avocet. This project required state-of-the-art scanning and inspection services to support ongoing maintenance and ensure the suction dredger’s optimal performance. With work conducted at both A&P Falmouth and Portsmouth, the project involved two key phases:

Phase 1: 3D Scanning of pump room and inboard suction pipe

Using the Leica RTC360 3D Laser Scanner, we completed the scanning in just half a day on-site in Falmouth. The captured data was processed and delivered within a day, providing a fully registered point cloud that offered Aggregate Industries a detailed digital representation of the pump room and suction pipe layout. This in turn allowed routine maintenance along with improvements to be made to the pipe. 

Phase 2: Whole vessel scanning and ultrasonic thickness measurements of dredge pump

The Leica RTC360 3D Laser Scanner and Cygnus 1 Ex UT Gauge were instrumental in completing this task. Over two days on-site, we scanned the entire vessel, capturing a colourised point cloud and high-resolution 3D imagery. The photos have since been used for asset management and can be referred to for future upgrades or engineering works. 

For the dredge pump casing, ultrasonic thickness measurements were meticulously taken to evaluate material thickness and identify potential wear or corrosion. The data was processed and compiled into a detailed report, delivered within one week.

Final result 

The A.I. Avocet plays a vital role in Aggregate Industries’ operations, and keeping it in peak condition is essential. Our precise 3D scanning and UT measurement services provided the necessary data to support informed maintenance and repair decisions, ensuring the vessel remains reliable and efficient.

This project demonstrates our commitment to delivering cutting-edge solutions tailored to the maritime industry’s unique challenges.

For inquiries about similar projects, contact us at Digital Dry Dock. 

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In March 2024, Digital Dry Dock began an exciting project with Alchemy Contracting to support the refit of Dorus Mor, a workboat critical to their operations. In this blog we outline the process, including initial scanning to lifting to stability analysis. 

Phase 1: Pre-refit survey

The project began with a 650-mile road trip each way to Oban, Scotland – a journey planned to ensure optimal weather conditions for the survey and to take in the stunning coastal scenery.

On March 20th, we conducted a detailed survey of the Dorus Mor, capturing comprehensive data to facilitate the refit process. This allowed us to create both a colour point cloud 3D representation of the vessel and a digital twin, to help Alchemy Contracting plan the refit effectively, communicate with subcontractors, and liaise with relevant authorities.

Phase 2: Lifting the vessel 

To ensure the safe crane lift of the vessel onto a steel cradle, we estimated the centre of gravity. Using a centreline slice of the point cloud data, we calculated the centre of area to inform critical lifting decisions. This step minimised risk and streamlined planning for the cradle setup.

Phase 3: Stability analysis 

In April 2024, we created a detailed mesh surface model of Dorus Mor, suitable for use with Max Surf naval architecture software. This model was integral for performing stability analysis, ensuring the vessel met all regulatory and operational requirements post-refit. This in turn enabled us to update the stability model for the vessel.

Phase 4: Crane feasibility study

Another major task was to assess the feasibility of relocating the onboard crane. We conducted a detailed study to determine if the proposed location was structurally sound and established safe loading limits. This analysis provided the client with confidence in their refit plans.

 Phase 5: Full CAD surface model 

The final milestone was completed in January 2025, when we delivered a full CAD surface model of the vessel. This included: 

• A high-precision 3D surface model for use in refit planning; 
• 2D sections and elevations extracted from the CAD model to support design and construction;
• General Arrangement Plan to provide an overview of the vessel’s layout, guiding the refit process.

Final result 

Through advanced digital techniques and collaboration we supported Alchemy Contracting in delivering a safe and efficient refit for Dorus Mor. From a detailed survey to crane feasibility and stability analysis, every step was designed to meet the highest standards of accuracy, safety and functionality.

For inquiries about similar projects, contact us at Digital Dry Dock. 

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Amongst Digital Dry Dock’s latest projects have been a charitable job for the MV Balmoral Trust. With the help of Sunbelt Rentals, who kindly loaned us two Leica RTC360 laser scanners and software licences, we were able to provide the Trust with up-to-date and highly accurate point cloud data and 360 panoramic images to help assist with the management of the vessel moving forward.

VIEW THE DATASET HERE

The MV Balmoral is celebrated as one of the last surviving examples of a traditional British coastal excursion vessel. Its history reflects the changes in British leisure travel over the decades and the challenges of preserving maritime heritage. It was fitting that she should be dry docked in the historically significant Albion Dock in Bristol.

The MV Balmoral Trust is actively working to preserve and restore the vessel so it can be operational again in the near future.

History of MV Balmoral

The MV Balmoral is a historic excursion ship with over seven decades of maritime service.

Construction and early years (1949-1959)

Built in 1949 by the shipbuilding company John I. Thornycroft & Company, her original purpose was as a passenger ferry between Southampton and the Isle of Wight.

Bristol Channel Service (1959-1980s)

After ten years of operation, the ship was purchased by P&A Campbell. The MV Balmoral became a popular vessel for day trips from Bristol to coastal resorts in South Wales and the West of England. Throughout the 1960s and 1970s she was well-known to holidaymakers looking for short cruises.

Withdrawal and rescue (1980s-1990s)

With the decline of passenger numbers on ferry excursions, the ship was withdrawn from service in 1980 and used temporarily as a floating restaurant. In the late 1980s, the MV Balmoral was saved from potential scrappage by the charity Waverley Steam Navigation Co., who saw value in preserving the vessel as a heritage excursion ship.

Return to service (1990s-2000s)

Following significant restoration work, MV Balmoral resumed a schedule of coastal excursions around the UK in the mid-1990s. However, mounting financial and operational challenges have led to several temporary withdrawals from service.

Current status

Since 2017 MV Balmoral has been moored alongside at Bristol Harbourside near the SS Great Britain. She has a growing roster of educational activities onboard, becoming a floating classroom and interactive environment for schools in the region. In recent years the future of MV Balmoral has become uncertain, and the MV Balmoral Trust is doing great work to preserve the ship, alongside public support and Heritage Lottery funding grants.

Why donate 3D digital scans to an out-of-service vessel?

After some years out of action, we hope to assist the MV Balmoral Trust to get the ship back in commercial sea-going classification in line with MCA (Maritime Coastguard Agency) regulations.

Over four hours Digital Dry Dock was able to provide full survey data, including 131 scans and 1.1 billion data points.

This data can be used to update all ships plans, including the General Arrangement Plan and the Fire and Safety Plan, so that the vessel can become operational. Scans can also be used to model the hull and used to predict her stability to get a new stability book.

Get involved

If you’d like to visit the MV Balmoral or contribute to the restoration and preservation of this historic vessel, there are regular volunteering days and opportunities to donate.

If you’re interested in our 3D digital imaging services, please get in touch or visit our website to learn more.

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Why ornamental half models?

Originally used by shipyards to communicate design features to vessel owners before they were made, half hull models are often found mounted on a board. They are exact scale replicas of one half of the ship’s hull, without the rigging or other fixtures. Whilst today boats are designed using computer modelling, half hull models are often still built as nautical art after the boat is completed. They may also be used in competitive sailing as trophies, or as gifts for sponsors or commercial owners. For some, half hull models are also seen as collector items, with some fetching extremely high prices on the market.

Digital Solutions for Displaying Naval Architecture

Digital Dry Dock can quickly produce a digital half hull model from any vessel’s point cloud or 3D scan data. Depending on the purpose of the model there is the option to either CNC mill or 3D print them from a range of materials.

When requested for decorative purposes, we can CNC mill the designs from wood, to provide an elegant, solid and quality replica. There are a range of finishes which can be provided, or the finish can be left ‘raw’ for finishing by the boat owner if required.

In the instances where half hull models are still used for design concepts, there is the option to 3D print the hulls at a significantly lesser cost. This can help with visualising design features, particularly when the appearance of the vessel is priority, without spending more than is necessary.

Alternatively, we can supply just the digital half hull model should the customer want to find their own route to manufacture or where digital visualisation is enough.

Results

Regardless of finish, all half hull models are exceptionally accurate to-scale replicas of vessels, which can be provided with a quick turnaround.  Our scanning technology makes creating a 3D half model a relatively quick and easy process, particularly when compared with traditional methods of working from manual measurements.

CNC Milling of Wood laminate method.

If you’re interested in a half model design concept or replica of your vessel, get in touch at info@digitaldrydock.co.uk to see how we can create one for you.

The post Digital Solutions for Naval Architecture 3 – Creating Ornamental Half Models appeared first on Digital Dry Dock Ltd.

Isles of Scilly Passenger Ferries

The Isles of Scilly is a remote archipelago, 28 miles from the Cornish mainland. With over 140 islands, the smallest no larger than a rock and the largest no bigger than three by two miles, the inter-island passenger ferries are an essential part of life in this remote corner of the United Kingdom. The ferries run services between the five inhabited islands – St Mary’s, Tresco, St Martin’s, Bryher and St Agnes. They also run routes to Samson, the largest of the uninhabited islands.

Earlier this year, five of the inter-island passenger ferries had their draught mark positions in question by the surveying authorities – the Maritime and Coastguard Agency (MCA) and a naval architect. Draught marks are used by the master to ensure that the vessel is not overloaded, as according to its stability book datums, before leaving port.

Digital Solutions for Complying with Naval Architectural Standards

 Being in a remote location, traditional methods of checking draught mark positions require boat owners in the Scillies to spend multiple days, or even weeks, travelling to mainland boatyards and having work carried out. To save the time, hassle and costs of doing so in addition to their annual haul out and maintenance period on the mainland, the ferry owners asked Digital Dry Dock if we could complete the work alongside the routine maintenance work.

By conducting a 3D laser scan survey of the vessels, we were able to create an accurate ‘as-built’ digital twin for each vessel, working around other contractors who were conducting GRP modifications, engineering works, antifouling and painting work. After scanning, we applied the stability book datums to the models, to determine where the draught marks should be compared to where they had been marked so far on the hull.

The next step was to produce a 2D CAD drawing which could be used to show the correct position, size and spacing of the marks. This drawing included measurements taken from the digital twin, which allowed us to position them with far greater accuracy than traditional methods calculated by hand, as well as saving ferry owners time and money by limiting their time on the dry dock.

The Result

With our method approved by the MCA we were able to CNC laser cut new marks and install them on the beach in St Mary’s, saving the vessel owners an additional trip to the mainland. Our methods also made it possible to avoid the arduous, time-intensive and costly process of manually levelling the vessels to ‘real world level’ before positioning the marks. By using 3-axis laser levels with a survey grade elevating tripod to lay them out, we were able to position the marks within an hour. These positions were then verified by the MCA before we installed them on the GRP hulls with a permanent mastic adhesive.

As a result, the naval architect and MCA are now satisfied that all five ferries’ draught marks comply with naval architectural standards.

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At Digital Dry Dock, we combine naval architecture with the latest digital technologies to significantly reduce project costs, schedules and the time vessels spend in dry dock. Often, our technology removes the need for time spent in dry dock altogether. In our latest blog series, Digital Solutions for Naval Architecture, we share some case studies with you to demonstrate how we gather data and how this helps our customers to build things in a smarter, faster way. In these three recent examples, we were able to support maritime businesses to deliver CAD support for new passenger ferries, to ensure compliance with naval architectural standards and to create 3D half models for use in design and decoration.

St Michael’s Mount Passenger Ferries

St Michael’s Mount is a tidal island in Mount’s Bay, Cornwall. Accessible via a set of iconic granite steps at low tide, as the tide rises the historic castle and its surrounding gardens can be accessed only via the passenger ferries. According to St Aubyn Estates, the Mount welcomes as many as 350,000 visitors per year. There are nine passenger ferries which service the island, operating between the end of March and the end of October.

The Mount had two new ferries built, ready for the start of the 2018 season. Happy with the outcome, they decided to produce four more identical boats. However, they wanted to switch boat builders and didn’t have any CAD drawings to work from, as the originals were custom small-scale builds.

Digital Solutions for Naval Architecture – CAD

We were approached by M2ED & St Aubyn Estates to see if we could help them replicate the new passenger ferries. Soon afterwards, we deployed to Mount’s Bay and scanned one of the two existing vessels to gather data for a complete set of CAD construction drawings and models. The combined interior and exterior scan took one day, including confined compartments such as the bilges and lockers. Digital Dry Dock was also able to scan the moulds, all of which made it possible to supply a set of detailed images and full-scale templates so the new builder could quickly understand the construction process.

The Result

Within one month of scanning, M2ED & St Aubyn Estates were supplied with the CAD package of 2D drawings and 3D models they needed to create exact replicates of their new ferries. The Mount then used the digital drawings & models for the build tendering process where, after having an opportunity to review the CAD work, local boat builders were asked to bid for the work. Once a builder was selected, Digital Dry Dock was available on request to supply any additional information needed. For example, to extract measurements from our scan results if there was something the builders were unable to get from the drawings.

St Aubyn Estate is the proud owner of two additional new passenger ferries, with the remaining two set to be ready to service the island in time for the end of this year.

The post Digital Solutions for Naval Architecture 1 – Rapid Delivery of CAD for New Passenger Ferries for St Michael’s Mount appeared first on Digital Dry Dock Ltd.

Digital Dry Dock are proud to take advantage of the Digitisation expertise on offer to Cornish businesses via Unlocking Potential & the E.U.

Digital Dry Dock received a Digital Transformation grant to purchase Cyclone 3DR Software, which enabled the business to create new services.

It is part-funded by the European Regional Development Fund

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Why is reverse engineering necessary?

 Before we start, it’s worth considering some of the reasons why reverse engineering may be necessary for boat builders, boat owners and other marine stakeholders. Here are some of the main reasons, all of which our digital laser scanning solutions can help you with:

• Existing designs may be drawn on paper or developed without drawings
• Existing CAD designs may not be accurate
• Existing CAD designs may be missing or lost
• Production moulds may have been bought from original creators without the CAD designs

 Click here to learn more about Digital Dry Dock’s services, and how we can reverse engineer CAD models for your vessel.

Point Cloud over Mesh Model

The Multimarine Project

Redesigning vessels to keep up with the latest trends and technologies is crucial to maintaining Multimarine’s reputation as ‘unique innovative and highly personalised boatbuilders’. On this occasion, our role was to create CAD models of the hull and deck structures of some of their vessels and full CAD models of some of their small production catamarans. These CAD models will now be used to design new variants of the existing craft, so that they can customise and fine tune the original designs.

How was the work carried out?

Ollie visited Multimarine and scanned a mixture of GRP moulds and GRP boats within the same day. He was able to use laser scanners to create digital twins of the vessels and to capture their hull and deck forms. From the point of scanning, the data was processed within two days to create 3D CAD models with an accuracy of less than 3 millimetres.

 What was the alternative to laser scanning?

 Without laser scanning, a skilled draughtsman would have needed to take painstaking manual point measurements along slices through the hull shape at known intervals. They would then ‘loft’ lines and surfaces through them to redraw a very similar representation of the subject. This would take days rather than hours and be far less accurate, regardless of the skill of the draughtsman.

How will Multimarine use these CAD drawings?

Once they received the 2D and 3D CAD drawings, Multimarine were able to design modifications on top of them, to improve the existing vessel design. This means they can create new production moulds, bespoke parts or new customisations with high accuracy and precision.

What did Multimarine have to say?

 “I’d like to thank again the team at Digital Dry Dock for the amazing scanning work we received the other week. We have been looking to digitise a variety of older vessels in our yard that did not have up to date CAD files. 

Ollie Graffy assisted us using scanning gear and point cloud mapping software, providing us with accurate hull and deck models. These models… will allow us to further hull development for resistance and stability assessments, while providing us a basis to develop new interior and deck configurations.”

– Luca, Multimarine Designer

To learn more about how we can help you with reverse engineering CAD designs and much more visit our website. Or get in touch at info@digitaldrydock.co.uk.

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Global supply, demand and shipping schedules amongst other things can often cause complications when sourcing vessel components. Delays on part arrivals can be frustrating, delaying project timelines or holding up port departure dates. Even more so, being unable to source parts at all can create unwelcome headaches for marine stakeholders, especially when the rest of the vessel and crew are ready.

Over the past twelve months Digital Dry Dock has been working to provide a solution to delayed or unavailable vessel parts. Using our 3D laser scanning technology, we are now able to handle everything from measuring and manufacturing to delivery, all within short timeframes.

Rapid supply of vessel components for all marine stakeholders

3D laser scanning presents a solution for shipyards, shipowners, ship operators, shipping agents and yacht agents when in need of rapid supply of custom-made vessel components. Using our state of the art laser scanning technology, we are able to scan complex parts, create precise 3D CAD models and work with our trusted CNC machinist subcontractors to create fit for purpose components in short notice. We are able to organise international logistics and customs clearances to avoid any unexpected delays in the delivery of parts. This process is also available to create components which are no longer manufactured.

Types of component supplied

As long as there is an existing part to work from, or detailed 3D CAD model, we can re create any vessel component. Using hand scanners, sometimes in conjunction with manual measurements and existing 2D drawings, Digital Dry Dock are able to create 3D CAD models with exceptional accuracy. Here are some examples of parts we have scanned and manufactured in recent months, from toilet seats to complex rig and hatch components.

Mast components and fittings

Using Creaform metrology grade scanners, we were able to provide accurate data to Rondal – industry leading superyacht supplier-on a section through a large carbon mast. This included the position of a pair of holes in relation to one another, so they could design parts to fit into the holes on each side of the mast.

In addition, Rondal sent us a 3D CAD model of a complex mast fittings which needed to be manufactured and supplied to a vessel in the Mediterranean. We were able to do so within a tight pre-Christmas timeline.

Electrical Switch Panels

Also, for a classic sailing yacht, Digital Dry Dock was able to make new fascias for the electrical switchboards. By scanning the panel, we were able to create CAD drawings which were used to CNC machine new fascias with correct and updated labelling.

Speeding up delivery timelines

Because we know the nature of the marine industry, we are happy to think outside the box when it comes to delivery timelines. We are able to consider timeframes that most other suppliers would not be able to, because we have developed strong relationships with international couriers and air freight companies. We can pull out all the stops to get a yacht in service at short notice, or go with a trusted conventional courier to keep the costs down. We work with our clients’ priorities and budgets to do everything we can to get a vessel seaworthy in a timeframe that works for them.

If you’d like to see how Digital Dry Dock’s 3D laser scanning services can help your vessel or business, please contact info@digitaldrydock.co.uk.

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