DARPA Plans to Advance Underwater 3D Printing of Concrete for Naval Bases

The U.S. Defense Advanced Research Projects Agency (DARPA) is seeking participation from industry and academia in a new study aimed at achieving underwater 3D printing of concrete in shallow and nearshore areas for the repair and construction of critical port facilities. The envisioned system will directly utilize seabed sand, clay, and seawater, reducing reliance on specialized equipment and external material transportation for traditional underwater construction.

Targeting Naval Bases and Maritime Facilities

DARPA states that while existing underwater concrete construction technologies are available, they are complex, costly, and cause significant environmental disruption, making them unsuitable for expeditionary or military operational scenarios. The new approach aims to conduct construction in shallow coastal areas and waters up to 100 meters deep, which could be used for the construction of ports, seawalls, artificial reefs, and could also serve to protect underwater oil and gas pipelines and communication cables.

The longer-term goal of this initiative is to lay the groundwork for a "fully autonomous system capable of deep-water operations." According to DARPA's vision, the system could directly undertake repairs near damaged maritime facilities in the future, reducing logistical burdens and enhancing recovery speed during wartime and post-disaster scenarios.

AI for Material Ratio Assessment

The project also plans to incorporate AI to determine the optimal ratios of seawater and sediment under different marine environments. Due to significant variations in sand, clay, and water conditions at different locations, the material combinations will directly affect the concrete's forming effectiveness and durability. DARPA hopes to enhance the adaptability of on-site construction through algorithms rather than relying on a single fixed formula.

In recent years, the U.S. military has been increasing its investment in autonomous systems, extending from aerial and ground unmanned platforms to logistics and engineering support. While there have been trials of land-based 3D printed structures, executing underwater construction with robotic systems is still seen as a new technological direction.

Background of Aging Maritime Infrastructure

DARPA's push for this research is also related to the aging of U.S. maritime infrastructure. Saltwater, humidity, storms, and corrosion continuously erode facilities such as docks, piers, and seawalls, which serve as both logistical nodes in peacetime and critical naval support points during wartime.

Public reports indicate that some U.S. maritime military facilities have been under long-term pressure. A report released last year mentioned that approximately 45% of the U.S. Coast Guard's maritime facilities, including docks and mooring facilities, have exceeded their expected service life.

In addition to this underwater construction plan, DARPA is also advancing another early study aimed at more accurately predicting the aging and failure modes of concrete infrastructure over decades. The agency provided $10 million in funding to the University of Colorado in 2023 for a nearly five-year study exploring how damaged facilities like airports, missile silos, and naval docks could possess "self-repairing" capabilities similar to biological systems.

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