Evergreen Additive Scales LFAM for Marine Tooling to Fielded Vessels

Source (All Images) | Evergreen Additive

Evergreen Additive (Brunswick, Maine, U.S.) was founded by staff research leaders at UMaine’s UMaine's Advanced Structures and Composites Center. The four co-founders had led development and testing of two 6-meter unmanned surface vessels (USVs) for the U.S. Office of Naval Research, demonstrating the use of large-format additive manufacturing (LFAM) to produce large composite structures faster, more efficiently and with less dependence on scarce skilled labor. The company now produces marine composite tooling and unmanned marine vessels and also provides engineering services to optimize designs for LFAM. It operates from an 8,000-square-foot headquarters and manufacturing facility with an initial equipment investment of about $1 million and plans for $5 million in additional funding over the next t3 years.

Early in 2026, the company completed installation and commissioning of its first CEAD Group (Delft, Netherlands) LFAM machine. In May 2026, Evergreen entered an exclusive supply agreement with Airtech Advanced Materials Group (Springfield, Tenn., U.S.). The latter will provide LFAM materials and technical support while Evergreen Additive will use Airtech products exclusively across its LFAM projects.

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“Our business relies on high-quality materials that have a predictable supply chain, which is why we’re partnering with Airtech,” says Kyle Warren, CEO of Evergreen Additive. (see CW’s plant tour of Airtech’s LFAM facility).

Shown here is Evergreen Additive's Flexbot. The bed is 2 × 12 meters and includes additive and subtractive operations.

Evergreen Additive has since expanded its manufacturing capacity, including a larger 2 × 12-meter build area by moving its robotic printer onto a rail. The company then printed four vessels in preparation for Exercise Northern Strike, reported to be one of the largest multi-domain training exercises in the U.S. Using the same robotic printing process despite differing hull forms and mission profiles, Evergreen Additive printed a gas-powered monohull, an electric monohull, an electric catamaran and a 6-foot target hull. This range of products shows how LFAM scales for versatility rather than focusing on a single product, says Warren. One hull was completed in a single day, illustrating the advantage of robotic printing over lengthy conventional composite processes and tooling lead times.

Evergreen Additive has also produced a composite catamaran configured for unmanned aircraft system (UAS) launch and recovery operations. The vessel’s 4 × 6-foot payload deck accepts rotary-wing and fixed-wing UAS and was built in a few weeks without tooling or molds.

Evergreen Additive is targeting two primary markets. The first is marine tooling and manufacturing aids for boatbuilders, including patterns and direct-use molds for hulls, decks and other large components, which can be delivered 50-75% faster than traditional methods. The second is USV for the U.S. Department of Defense (DOD). The company won a $42,000 award through the Defense Innovation Unit’s dual-use university accelerator program and is also supported by MTI Business Innovation funding. More recently, the company has also been contracted by the DOD to establish LFAM capabilities for maritime applications within Maine’s defense industrial base.

Evergreen Additive plans to create at least 10-12 full-time jobs over the next 5 years and to continue expanding its capabilities.