Australian company Hyperion Systems has unveiled the southern hemisphere’s first 3D-printed uncrewed surface vessel (USV), marking a major milestone for advanced manufacturing and autonomous maritime capability in Western Australia (WA).
Designed by Western Australian marine architect Versatile Marine and equipped with autonomy software from Greenroom Robotics, the ASTRA 460 will be built by Hyperion Systems in Henderson, Western Australia. The project highlights an approach aimed at faster and more cost-effective vessel production while supporting domestic industrial capability.
It was officially presented at the Indian Ocean Defence and Security (IODS) conference by WA Defence Minister Paul Papalia, alongside Hyperion’s deployable “factory in a box” system, TitanCell, shown publicly for the first time.
Subject to successful completion of sea trials beginning later this month, the fully autonomous vessel will be capable of speeds of up to approximately 40 knots, with a cruising speed between 20 and 30 knots and a range of around 180 to 200 kilometres. It will be designed for multi-mission operations, including surveillance, security tasks, and the covert transport of small teams, with modular payload options and the ability to operate in a range of sea conditions.
The ASTRA hulls will be produced using large-format additive manufacturing (LFAM) and recycled polymer waste. The program is being delivered by a consortium led by Hyperion Systems, with integration support from Australian stakeholders.
The vessel’s autonomous navigation and control system will be provided through Greenroom Robotics’ GAMA platform, which is designed to be scalable and adaptable across different unmanned surface vessel configurations.
Hyperion CEO Joshua Wigley said the hull can be manufactured in around 40 hours using LFAM 3D printing, compared with approximately four to six weeks required for traditional boat-building methods.
He added that this significant reduction in build time demonstrates the potential of additive manufacturing to accelerate maritime capability development and strengthen sovereign industrial capacity.
Greenroom Robotics co-founder and COO Harry Hubbert stated the company’s autonomy stack is well-suited to rapidly reconfigurable, 3D-printed USV platforms.
He noted that in contested environments, the ability to quickly adapt vessels to changing mission requirements could provide an operational advantage, enabling near real-time customisation for specific operational needs. He also said that vessels could be printed, equipped with autonomy systems, and deployed within a matter of days, supporting faster and more scalable maritime capability delivery.
The ASTRA 460 is expected to be among the first LFAM 3D-printed unmanned surface vessels of its kind, with a larger 8-metre prototype planned for delivery to a European navy for use in a major naval exercise in 2026.