CASE STUDY

Discover how MiniLab is revolutionizing hydrofoil technology with sustainable materials, 3D printing, and real-world maritime testing to shape the future of offshore racing.

CHALLENGES:

Custom Manufacturing for High-Stress Components

Reducing Production Time and Weight Without Increasing Costs

MAIN INFORMATION:

Company

Minilab

Technology

Selective Laser Sintering (SLS)

Industry

Mobility

About the Company:

MiniLab, founded by Adrien Marchandise, is an innovative collaborative testing platform dedicated to advancing sustainable technologies for navigation. The company is currently working on its first project: testing recyclable thermoplastic composite hydrofoils to develop lower-impact solutions for offshore racing. With a collaborative approach, MiniLab and its consortium—comprising Avel Robotics, ComposiTIC, IRMA, Diab, and Victrex—work alongside partners such as Sculpteo to bring together expertise in advanced materials, robotics, and composites. Committed to reducing the environmental footprint of the maritime industry, the MiniLab consortium is at the forefront of designing, manufacturing, and testing high-performance, sustainable solutions that are shaping the future of competitive sailing.

Overview of Project

About the Project:

The MiniLab hydrofoil project is an innovative initiative in the maritime industry, aiming to revolutionize hydrofoil technology with a strong focus on sustainability. At the core of this project are two key aspects: designing and manufacturing hydrofoils using recyclable thermoplastic materials, and conducting real-world testing aboard the MiniLab test boat. The goal is to demonstrate the feasibility of this technology for a repurposed Mini 6.50-class sailboat and to prove the eco-performance of these new materials. One of the project’s main innovations lies in the use of cutting-edge materials and technologies. The hydrofoils are made from thermoplastic composites, which are both lightweight and fully recyclable—a significant advancement over traditionally used materials. To assess performance and durability, the hydrofoils are equipped with integrated fiber-optic sensors that measure stress and elasticity under extreme conditions. Additionally, acoustic sensors provide real-time damage monitoring, ensuring safety and reliability in use.

Another key ecological aspect of the project is the opportunity to give offshore racing boats a “second life.” Many older-generation racing boats are no longer competitive compared to the latest designs. By equipping these boats with hydrofoils, their performance can be significantly enhanced—avoiding the environmental impact of building an entirely new competition vessel. MiniLab partnered with Sculpteo to manufacture the upper and lower brackets that house the retractable foils. These components require custom manufacturing, as the assembly design relies on materials with high compressive strength—critical for supporting the boat’s entire weight. The testing and validation process is both rigorous and dynamic. These state-of-the-art hydrofoils will undergo real-world trials on a 6.5-meter Mini Class offshore racing sailboat, where they will be subjected to extensive sea trials and mechanical testing. The first major tests are scheduled for March 2025, with further validation planned during the prestigious Mini Transat 2025—a grueling 4,000-nautical-mile solo transatlantic race that will provide the ultimate test of the hydrofoils’ performance in extreme racing conditions. Thanks to 3D printing, the production timeline was reduced from three weeks to just one, while also decreasing the overall weight by 20%—all while maintaining competitive costs.

Overcoming Challenges:

Collaboration is one of the key strengths of the MiniLab project, enabling the team to overcome critical manufacturing challenges. By partnering with Sculpteo, MiniLab successfully developed custom upper and lower brackets using raw SLS PA12, a material chosen for its high compressive strength and durability—essential for supporting the boat’s weight. Traditional manufacturing methods would have been costly and time-intensive, but with 3D printing, these components were produced with precision in just one week, cutting production time by two-thirds. Additionally, the optimized design reduced weight by 20% without compromising strength, a crucial factor in hydrofoil performance. Alongside Sculpteo, Avel Robotics contributed expertise in composite design and automated fiber placement, while ComposiTIC and IRMA advanced polymer technologies and additive manufacturing solutions. Victrex and Diab supplied the high-performance thermoplastic polymers essential for durability and recyclability. Together, these partners provided the technical innovations needed to make sustainable, high-performance hydrofoils a reality.

Future Developments:

The MiniLab project is not limited to materials; it is designed to become a collaborative testing platform for the maritime industry. Sails, energy systems, navigation equipment—anything that needs to be tested under real, demanding offshore conditions can be trialed aboard the test boat. Thanks to MiniLab, companies will have a unique testing ground to validate their innovations against the challenges of the open sea. Beyond creating sustainable hydrofoils for immediate use in ocean racing, the vision of the MiniLab project extends to the future of competitive sailing. Avel Robotics plans to deploy this technology on a larger scale to produce, by 2026/2027, larger thermoplastic composite hydrofoils designed for IMOCA and ULTIM class racing yachts. This expanded project will be funded by the Brittany Region and will include a new partner, Mer Concept, facilitating broader dissemination of their innovations and opening up new prospects for enhancing sustainability in a wider range of maritime sectors. Ultimately, the MiniLab project represents a first step toward reducing the environmental impact of offshore racing. By developing the first recyclable hydrofoils and advancing technological innovations, the project sets new standards for the maritime industry and shapes the future of navigation.

What They Say:

How has your experience been working with Sculpteo?

Working with Sculpteo was seamless. Their fast and precise 3D printing services allowed us to bring our project to completion! I highly recommend them for their efficiency and the quality of their work.

Adrien Marchandise

CEO Minilab

They trust us

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