3D-printed boat fenders made from TPU: Newsfender focuses on digital manufacturing and the circular economy

By using large-format 3D printing technology, the company Newsfender EU is addressing the ecological weaknesses of conventional boat fenders. These are often made from materials such as polyurea, which are difficult to recycle, cause high material losses during production and can be potentially harmful to health. Newsfender takes a different approach: the additively manufactured fenders are made from thermoplastic polyurethane (TPU), which is fully recyclable and suitable for on-demand, digital production.

Production takes place on industrial 3D printing systems from BigRep, which are designed for the use of large-volume workpieces. The fenders are printed monolithically, without cavities or additional components such as valves, directly from TPU. This not only enables individual adjustments in shape and size, but also optimized shock absorption. In addition, each fender has an integrated NFC chip for ownership identification and traceability as part of a digital product passport.

Another technical feature is the UV-reactive material used, which increases the visibility of the fenders in low light conditions. Newsfender has also established a take-back and recycling concept that allows the material to be reused for new prints. This allows closed material cycles to be realized – a key aspect in the current discussion about sustainable production in the maritime sector.

“Our solution shows how industrial production can be rethought – locally, efficiently and completely circular,” says Fernando Fortunato, CTO at Newsfender EU.

The printed fenders are already being used by authorities such as the Guardia Civil and the Olympic port of Barcelona. Newsfender now operates its own print farm with several BigRep systems and pursues a decentralized production model that is specifically geared towards digital and sustainable marine equipment.

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