Wave energy propels Australian manufacturing as new project sets sail

A new R&D project between Australian Composites Manufacturing (ACM CRC), Ocius Technology and the University of New South Wales (UNSW) is set to optimise the use of wave energy for propulsion, harnessing energy for underwater flippers for unmanned surface vessels (USVs).

Bluebottle-class USVs are innovative autonomous solutions developed by Ocius for continuous maritime surveillance. The technology has applications across oil and gas, security and scientific research, and is enhancing a range of maritime defence missions such as mine clearance, patrolling, environmental monitoring and search and rescue operations.

As unmanned ocean vessels, it is imperative that USVs operate efficiency in the water at all times and navigate safely in open ocean transport channels. As a fully renewable surface vessel powered by solar, wind and wave energy, the Ocius Bluebottle is currently operating well but has limitations when used in strong winds.

The wave energy used by the Bluebottle is facilitated by a fibre-reinforced laminated composite rudder, or 'flipper', at the front of the vessel, which provides passive thrust. This ACM CRC project aims to design and manufacture the next generation composite flipper for these vessels, for optimal propulsion and thus operation even in the toughest weather conditions and no matter what the state of the sea.

"The tailorable stiffness of composite materials provides a unique opportunity to achieve additional thrust from flapping and morphing structures. Our R&D project exemplifies the CRC's vision to unite its composite industry partners with ACM's world-class academic researchers and deliver innovation at the forefront in automated manufacturing of advanced composites", says Professor Ganga Prusty, Director of Research at ACM CRC.

Indeed, the project will leverage an innovative automated manufacturing procedure, integrating multidisciplinary techniques including scientific computing, optimisation, artificial intelligence and advanced manufacturing.

Robert Dane, CEO of Ocius, is enthusiastic about the possibilities of this project with the company already having a strong history in conceiving, funding and delivering difficult, innovative, high-tech, award-winning projects with remarkable outcomes.

"Ocius is excited about working with UNSW and the ACM CRC on this project", he says. "The 'rudder flipper' came out of biomimicry and was developed by trial and error into a third method of propulsion on a Bluebottle Uncrewed Surface Vessel besides sun and wind. It also acts as a 'sea anchor' in bad weather pointing the bow into high seas which can go on for days. So the flipper needs to have properties of strength, resilience and memory and this 3-year project with ACM CRC will put scientific rigour around the design and manufacture and turn it into a real 'superpower'."

UNSW Dean of Engineering, Julien Epps, attended the recent project signing ceremony, and concluded, "This is an excellent example of an industry-university partnership. Through close and sustained collaboration, the partnership has accelerated research translation, promoted the adoption of innovations, and provided valuable industry experience for university students and graduates, who are now supporting the partnership to scale even further."

"Through this CRC project, UNSW is extending its relationship with Ocius with a clear focus on the commercialisation of renewables and low emissions technologies. Outcomes will create new supply chains and employment in the Australian advanced manufacturing sector and reduce international supply vulnerabilities," adds Jamie Conyngham, UNSW's Director, Business Development and Commercialisation.

Associate Professor Fangbao Tian, the project's Chief Investigator, explains, "The UNSW Canberra Flow Science team has been developing advanced computational fluid dynamics tools for multi-process interactions over the last decade. As an important element of digital twins in engineering, advanced computational fluid dynamics will be used with artificial intelligence, optimisation and biomimetic knowledge of aquatic animals to design flipper-based propulsors of superior performance in terms of thrust and reliability."

Simulation technology development could also be applied to aero and hydrodynamic simulation of composite structures, such as surfboards, with improved efficiency of design and manufacturing guidance for robust flippers and similar products putting Australia at the forefront in smart and automated manufacturing. 

IMAGE CAPTION: Project signing ceremony, January 2024. Ready to develop the next generation of composite flipper. From L-R: Iain Walker - ACM CRC, Manager Business and Commercial | Associate Prof. Garth Pearce - UNSW (ACM CRC, Program Leader) | Prof. Julien Epps - UNSW, Dean of Engineering | Prof. Ganga Prusty - ACM CRC, Director of Research | Jamie Conyngham - USNW, Director of Business Development and Commercialisation | Dr Steve Gower - ACM CRC, CEO | Robert Dane - Ocius, CEO | Josh Grosser - Ocius, Field Engineer | Catherine Lloyd - Ocius, CFO | Nada Abdelhamid - Ocius, Accountant | Connie Severino - ACM CRC, EA and Events Coordinator