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Press Releases
Press Release
NEXT-GEN MANUFACTURING WITH A*STAR: POWERING INDUSTRY THROUGH INNOVATION AND AI
15 Oct 2025
The Agency for Science, Technology and Research (A*STAR) brings innovation to life through collaborations with industry, including small and medium-sized enterprises (SMEs) and multinational companies (MNCs). Together, they co-develop advanced manufacturing technologies that address real-world challenges and create tangible business impact.
Through these collaborations, cutting-edge research is translated into practical solutions embedded within factories and operations, enhancing efficiency, reducing costs and strengthening competitiveness. By integrating innovation across production and supply chains, A*STAR helps companies transform their businesses today while building stronger foundations for future growth.
Through these collaborations, cutting-edge research is translated into practical solutions embedded within factories and operations, enhancing efficiency, reducing costs and strengthening competitiveness. By integrating innovation across production and supply chains, A*STAR helps companies transform their businesses today while building stronger foundations for future growth.
From reimagining traditional marine propeller manufacturing processes to developing next generation surface treatment solutions and AI-driven factory intelligence, A*STAR’s collaborations and research are shaping the future of manufacturing in Singapore and beyond.
MENCAST: FROM CARBON TO SILICON IN MARINE INNOVATION
Singapore is the world’s busiest port by shipping tonnage, with around 140,0001 vessels arriving annually. To stay competitive in providing repair and maintenance services for these vessels—amid shifts in manpower, material costs, and international competition—local companies must innovate to offer higher value-added products and services.
- 20-30% increase in productivity in propeller manufacturing, under the ongoing Mencast – A*STAR Joint Lab
- Bridging craftmanship with computation, like digital design, AI, and additive manufacturing, with A*STAR and NAMIC’s support
- New revenue opportunities in global supply chains with the development of new capabilities and a breakthrough additive manufacturing process receiving industrial validation
- Reskilling local talent to move from traditional foundry work to smart manufacturing
Mencast Marine, a Singapore-based SME serving the offshore and marine industries, is redefining propeller design and manufacturing through its transformation journey from Carbon to Silicon. With over 40 years of expertise, Mencast is evolving from traditional foundry processes into a leader in intelligent marine engineering.
Through its collaboration with A*STAR, the company integrates digital design, artificial intelligence (AI), and additive manufacturing (AM) into design and production. These innovations have culminated in the successful development of AI-optimised, additively manufactured propellers—greener, quieter, and more efficient than conventional designs, as well as the shift from labour-intensive sand casting2 to advanced Wire Arc Additive Manufacturing (WAAM) and hybrid laser-wire/powder technologies, enabling faster production, reduced material waste, and unprecedented design flexibility.
Through its collaboration with A*STAR, the company integrates digital design, artificial intelligence (AI), and additive manufacturing (AM) into design and production. These innovations have culminated in the successful development of AI-optimised, additively manufactured propellers—greener, quieter, and more efficient than conventional designs, as well as the shift from labour-intensive sand casting2 to advanced Wire Arc Additive Manufacturing (WAAM) and hybrid laser-wire/powder technologies, enabling faster production, reduced material waste, and unprecedented design flexibility.
Mencast’s transformation bridges craftsmanship and computation, positioning Singapore as a hub for intelligent, sustainable marine propulsion. By embracing AI and AM, Mencast exemplifies how traditional industries can thrive in the silicon economy, driving forward a new era of precision, performance, and sustainability in maritime design and manufacturing.
Mencast’s First Step into Additive Manufacturing
Mencast’s additive manufacturing journey began in 2019 through a collaboration with the National Additive Manufacturing Innovation Cluster (NAMIC), a national platform hosted by A*STAR, to leverage the WAAM system funded by NAMIC and developed by the Singapore University of Technology and Design (SUTD). WAAM is a production process used to create or repair metal components by using an electric arc as a heat source to melt metal wire, depositing material layer by layer to build complex parts directly from digital designs. Through this collaboration, Mencast successfully produced and piloted Singapore’s first 3Dprinted marine propeller for a small boat sea trial — a milestone in additive manufacturing for the marine industry.
Mencast – A*STAR Joint Lab
In 2023, Mencast established a joint lab with A*STAR, tapping into the capabilities of the A*STAR Singapore Institute of Manufacturing Technology (A*STAR SIMTech) and A*STAR Institute of High Performance Computing (A*STAR IHPC) to modernise the production and design of propellers, and enable customised designs for diverse customer needs. The collaboration aims to strengthen Mencast’s in-house technical and design capabilities, and create innovative, customised products.
In 2023, Mencast established a joint lab with A*STAR, tapping into the capabilities of the A*STAR Singapore Institute of Manufacturing Technology (A*STAR SIMTech) and A*STAR Institute of High Performance Computing (A*STAR IHPC) to modernise the production and design of propellers, and enable customised designs for diverse customer needs. The collaboration aims to strengthen Mencast’s in-house technical and design capabilities, and create innovative, customised products.
The Mencast – A*STAR Joint Lab focuses on two key capabilities:
- Breakthrough in Additive Manufacturing of Marine Propellers
The team has developed a breakthrough WAAM process specifically tailored for large-scale marine components such as propellers. This innovation dramatically reduces material waste, and enables near-net-shape fabrication, producing parts that are almost in their final form and require minimal finishing or machining. Using robotic WAAM, propellers are built layer by layer directly from bronze alloy feedstock, cutting production time by nearly half compared to conventional casting. The process enables the creation of lighter, more efficient, and more sustainable propellers while reducing manual processes. The use of WAAM reduces the carbon footprint of producing each mid-size (around 200kg) propeller by 1,743 kg CO₂-eq — a 36% reduction — equivalent to driving a battery electric vehicle for about 9,500km.
The team has produced the world’s first fully additively manufactured ship propeller made entirely from WAAM bronze alloy. The propeller achieved full certification from both the American Bureau of Shipping (ABS) and Lloyd’s Register (LR), demonstrating the technology’s readiness for marine-class applications and marking a global milestone for additive manufacturing in the maritime sector. This milestone validates the structural integrity and reliability of additively manufactured propellers, paving the way for Mencast to commercialise next-generation, high-performance propellers with shorter lead times and improved sustainability.
Building on this success, Mencast is collaborating with partners such as ABS to develop industry standards and pilot projects that will accelerate the adoption of additive manufacturing in the maritime sector.
- Design and Simulation of Marine Propellers
The team has developed an integrated design optimisation framework that unites physics-based simulation with AI-driven optimisation algorithms, enabling rapid design and refinement of marine propellers before production. This system provides a compute-at-scale environment for achieving first-time-right solutions, allowing precise optimisation of complex propeller geometries to deliver higher thrust, improved hydrodynamic efficiency, and reduced fuel consumption. Mencast is adopting Generative AI to design propellers that achieve 5.6% to 13.8% higher efficiency across the typical operating speeds of marine propellers, resulting in significant reductions in carbon emissions and operating costs.
By significantly accelerating the design cycle and enhancing customisation capabilities, the team can create high-performance propellers precisely matched to each vessel’s operational profile. This approach strengthens competitiveness in nextgeneration marine propulsion, combining engineering precision with digital intelligence to achieve superior performance and sustainability.
Industrial validation of breakthrough WAAM process
In addition to propeller production, the WAAM process was successfully applied to the reinforcement of die-casting sets for Rolls-Royce. The process was fully validated by Rolls-Royce, which subsequently appointed Mencast as its local service provider—a strong endorsement of the industrial-grade quality and reliability of the WAAM-reinforced components.
This transformation has also reskilled the workforce, equipping engineers and technicians with expertise in robotic systems, advanced design software, and digital process control. The result is a more productive, future-ready team driving the transition from traditional foundry work to intelligent manufacturing.
ABRASIVE ENGINEERING: TRANSFORMING FROM SERVICE PROVIDER TO TECHNOLOGY-DRIVEN PRODUCT OWNER
Abrasive Engineering (AE), which offers surface enhancement services, was traditionally a service-focused business with more than 70 per cent of its revenue coming from services and trading. Through its collaboration with A*STAR, AE has steadily transformed from a service-focused business into a technology-driven product owner in surface enhancement systems, which are widely used in aerospace, energy and medical industries, and more than doubled its revenue to S$12 million.
The collaboration not only addressed the challenges that AE faced in product development speed, precision, and digital integration, but also delivered a breakthrough product that strengthened AE’s technological capabilities and sharpened its competitiveness as an industrial product owner. It further transformed AE’s culture and workforce, fostering a stronger drive for innovation.
Abrasive Engineering (AE), which offers surface enhancement services, was traditionally a service-focused business with more than 70 per cent of its revenue coming from services and trading. Through its collaboration with A*STAR, AE has steadily transformed from a service-focused business into a technology-driven product owner in surface enhancement systems, which are widely used in aerospace, energy and medical industries, and more than doubled its revenue to S$12 million.
The collaboration not only addressed the challenges that AE faced in product development speed, precision, and digital integration, but also delivered a breakthrough product that strengthened AE’s technological capabilities and sharpened its competitiveness as an industrial product owner. It further transformed AE’s culture and workforce, fostering a stronger drive for innovation.
Abrasive Engineering – A*STAR Joint Labs
In 2020, AE launched its first joint lab with A*STAR to develop next-generation precision valves and automated blasting processes. The three-year joint lab has since delivered significant impact including:
- Creation of six new product lines, including the world’s first microwave media dosing unit (patented by AE and A*STAR) and automated sandblasting systems. These systems were sold in Singapore and globally.
- Generated S$3.5 million revenue increase during the joint lab, contributing to 28 per cent of AE’s total revenue during this period
- Creation of nine R&D jobs and four new Ips
In October 2025, Abrasive Engineering launched the second phase of its joint lab with A*STAR to develop next-generation surface treatment solutions, fuelling AE’s global growth and a projected S$25 million in revenues by 2030.
Empowering the Workforce
Dave, a long-serving technician at Abrasive Engineering, once focused on repetitive manual programming tasks. Through the company’s partnership with A*STAR, he was retrained to operate and optimise digital systems, moving into higher-value roles in programming, monitoring and data analysis. Today, he not only thrives in his new role as an IoT Manager but also mentors younger colleagues, showing how digitalisation empowers workers to grow with technology rather than be displaced by it.
Dave, a long-serving technician at Abrasive Engineering, once focused on repetitive manual programming tasks. Through the company’s partnership with A*STAR, he was retrained to operate and optimise digital systems, moving into higher-value roles in programming, monitoring and data analysis. Today, he not only thrives in his new role as an IoT Manager but also mentors younger colleagues, showing how digitalisation empowers workers to grow with technology rather than be displaced by it.
ADVANCING AI IN MANUFACTURING: BUILDING INTELLIGENT AND ADAPTIVE FACTORIES
Innovation in AI, automation and digitalisation continues to transform how companies manufacture, driving productivity, boosting resilience, and creating higher-value jobs. A*STAR’s AIMie, an agentic AI solution, demonstrates how human-AI collaboration can enhance manufacturing operations. Unlike traditional automation systems that follow fixed instructions, AIMie can reason, adapt, and coordinate tasks in real-time in response to changing factory conditions. It supports operators in areas such as predictive maintenance, production scheduling, and operational decision-making, optimising operations across complex and variable environments. The solution can also be deployed at scale across diverse manufacturing sectors.
By continuously learning from data and human feedback, AIMie enables the workforce to focus on higher-value analytical and supervisory roles. As part of the Sectoral AI Centre of Excellence for Manufacturing (AIMfg) launched in 2024, AIMie embodies A*STAR’s vision of human-centric AI, empowering people to work smarter alongside technology and enabling factories of the future to become more intelligent, flexible and adaptive.
Innovation in AI, automation and digitalisation continues to transform how companies manufacture, driving productivity, boosting resilience, and creating higher-value jobs. A*STAR’s AIMie, an agentic AI solution, demonstrates how human-AI collaboration can enhance manufacturing operations. Unlike traditional automation systems that follow fixed instructions, AIMie can reason, adapt, and coordinate tasks in real-time in response to changing factory conditions. It supports operators in areas such as predictive maintenance, production scheduling, and operational decision-making, optimising operations across complex and variable environments. The solution can also be deployed at scale across diverse manufacturing sectors.
By continuously learning from data and human feedback, AIMie enables the workforce to focus on higher-value analytical and supervisory roles. As part of the Sectoral AI Centre of Excellence for Manufacturing (AIMfg) launched in 2024, AIMie embodies A*STAR’s vision of human-centric AI, empowering people to work smarter alongside technology and enabling factories of the future to become more intelligent, flexible and adaptive.
A*STAR celebrates International Women's Day
From groundbreaking discoveries to cutting-edge research, our researchers are empowering the next generation of female science, technology, engineering and mathematics (STEM) leaders.
Get inspired by our #WomeninSTEM