Reverse engineering and manufacturing of 3 CPP blades
OEM Level quality without affecting Propulsion System Performance
Minimal Vessel downtime, maximum cost savings
Project Snapshot
A 3,100 DWT RoRo vessel, 96 m in length, equipped with two CPP Propellers with total output of 6,360 HP at 242 RPM, suffered catastrophic damage to three of the four propellers blades The blades were beyond repair and the OEM quoted a delivery time exceeding six months for spares, a delay that would have severely impacted the vessel, which was under charter, resulting in significant financial losses.
Challenge
The project presented an exceptional engineering challenge. CPP blades have highly complex three-dimensional geometries, with continuously varying twist, camber, thickness, and pitch along their span. Their manufacture demands premium-quality casting, five-axis CNC machining, and extremely tight dimensional tolerances to ensure optimum hydrodynamic performance, structural integrity, and reliable operation of the CPP system. In addition, the intricate blade-root geometry is essential for accurate hub assembly and sealing. Even minor deviations can cause cavitation, vibration, increased fuel consumption, and premature wear, making rigorous quality control essential throughout production.
Complex Manufacturing & Engineering Challenges
Reverse engineering from a single original CPP blade
High-resolution 3D laser scanning and digital twin development
Precision casting and dedicated five-axis CNC machining
Custom machining strategy for complex blade-root geometry
Comprehensive dimensional inspection and NDT verification
OEM-equivalent performance and quality
CPP Blade Reverse Engineering Workflow Overview
Original Blade Assessment
Reverse engineering initiated from a single original CPP blade.
3D Scanning & Digital Twin Pattern Manufacturing
High-resolution 3D laser scanning and digital model development.
Casting & CNC Manufacturing
Precision casting followed by dedicated 5-axis CNC machining.
Complex Blade-Root Machining
Custom machining strategy for the blade-root geometry.
Inspection & NDT Verification
Comprehensive dimensional inspection and non-destructive testing.
OEM Quality Validation
Verification of OEM-equivalent geometry, performance, and quality.
Results
✔ Complete reverse engineering and manufacturing.
✔ More than 80% reduction in lead time compared to OEM delivery.
✔ Sea trials confirmed smooth, vibration-free operation.
✔ Vessel returned to service with minimal downtime.
✔ OEM-equivalent quality and reliability at a substantially lower cost.
Why Rely on KIMI
KIMI delivers advanced engineering repair solutions for critical propulsion components, combining heavy-duty machining capability, precision restoration technologies, and certified quality control under demanding marine operational conditions.
Advanced reverse engineering through 3D scanning, CAD modelling, and precision manufacturing.
Complete in-house capabilities with ESYD-accredited quality control and advanced CNC machining.
OEM Alternative that delivers obsolete and complex components with substantially reduced lead times.
Proven Excellence in manufacturing OEM-equivalent spare parts for the marine industry since 1984.