3D-printed sensor array detecting underwater object.

Unlock Underwater Secrets: How 3D Printing and Smart Sensors Revolutionize Ocean Exploration

Lena Voss in Tech & Innovation June 2025 • 4 min read.

"Dive into the future of ocean sensing with cutting-edge 3D-printed sensor arrays that mimic nature's lateral line, offering a cost-effective solution for underwater object localization."

Our oceans hold countless mysteries, resources, and ecological importance, yet exploring them presents significant technological challenges. Traditional methods of underwater detection, such as sonar, often grapple with environmental interference and sophisticated stealth techniques. This necessitates innovative solutions that can overcome these limitations and provide more effective means of underwater sensing.

Inspired by the lateral line system found in fish—a sensory system that detects pressure changes in the surrounding water—scientists are developing bio-inspired technologies that mimic this natural ability. These new approaches use pressure sensors to analyze the spatiotemporal information of the hydrodynamic environment, offering a way to perceive underwater objects without being hindered by the constraints affecting sonar.

Recent advancements in 3D printing have opened new avenues for creating these sophisticated sensor arrays. By leveraging 3D printing, researchers can rapidly prototype and customize sensor designs, making it easier and more affordable to explore different configurations and materials. This synergy between bio-inspired design and advanced manufacturing techniques is paving the way for a new era of underwater exploration.

The Power of 3D-Printed Sensor Arrays

3D-printed sensor array detecting underwater object.

At the heart of this technological leap is the pressure sensor array. To effectively detect and interpret underwater signals, these arrays must be both sensitive and waterproof. One sensor that meets these requirements is the MPVZ5004GW6U from Freescale, which offers a measuring range of 0-3.92 kPa and a sensitivity of 1 V/kPa. However, the real innovation lies in how these sensors are arranged and protected using 3D printing.

Traditional methods of creating sensor arrays are often complex and costly, especially when customization is needed. 3D printing provides a streamlined solution, allowing researchers to create complex shapes and precisely position sensors within a protective structure. This not only reduces waste and material costs but also speeds up the prototyping process, enabling faster iterations and improvements.

The benefits of using 3D printing for sensor array fabrication include:

Customization: Arrays can be tailored to specific research needs.
Cost-Effectiveness: Reduces material waste and labor costs.
Rapid Prototyping: Accelerates the design and testing phases.
Material Innovation: Allows the use of environmentally friendly materials like PLA.

In a recent study, a team of researchers designed a linear sensor array composed of nine pressure sensors, each strategically placed to maximize signal detection. The array was encased in a 3D-printed shell made from polylactic acid (PLA), a renewable and biodegradable material. This design allowed for precise sensor placement and provided a waterproof barrier, essential for underwater applications. The result was a highly sensitive and durable sensor array capable of detecting subtle pressure changes indicative of nearby objects.

Future Implications and Applications

The fusion of 3D printing and sensor technology is not just a theoretical advancement; it has practical implications for a variety of fields. From environmental monitoring to marine archaeology, the ability to accurately locate objects underwater opens up new possibilities for exploration and discovery. As sensor technology continues to evolve and 3D printing becomes more accessible, we can expect even more innovative solutions that leverage these tools to unlock the secrets of the ocean.

About this Article -

This article was crafted using a human-AI hybrid and collaborative approach. AI assisted our team with initial drafting, research insights, identifying key questions, and image generation. Our human editors guided topic selection, defined the angle, structured the content, ensured factual accuracy and relevance, refined the tone, and conducted thorough editing to deliver helpful, high-quality information.See our About page for more information.

This article is based on research published under:

DOI-LINK: 10.1109/icma.2018.8484566, Alternate LINK

Title: Dipole Source Localization Based On Least Square Method And 3D Printing

Journal: 2018 IEEE International Conference on Mechatronics and Automation (ICMA)

Publisher: IEEE

Authors: Xin Lin, Yong Zhang, Mingjiang Ji, Xiande Zheng, Kehong Lv, Jing Qiu, Guanjun Liu

Published: 2018-08-01

Everything You Need To Know

How does the bio-inspired approach using pressure sensors compare to traditional sonar for underwater object detection?

Bio-inspired sensor arrays, modeled after the lateral line system in fish, offer advantages over traditional sonar by analyzing the spatiotemporal information of the hydrodynamic environment. This allows them to perceive underwater objects by detecting subtle pressure changes, potentially overcoming limitations such as environmental interference and stealth techniques that can hinder sonar's effectiveness. Unlike sonar, which relies on sound waves that can be reflected or absorbed, these sensor arrays focus on pressure changes, providing a different modality for underwater sensing.

What is the significance of using polylactic acid (PLA) in the fabrication of 3D-printed sensor arrays for underwater applications?

The use of polylactic acid (PLA) in 3D-printed sensor arrays is significant due to its properties as a renewable and biodegradable material. Encasing sensor arrays like the linear sensor array composed of nine pressure sensors using PLA shells helps ensure that the technology has a lower environmental impact compared to traditional materials. This aligns with the goals of environmental monitoring and sustainable ocean exploration, creating a balance between technological advancement and ecological responsibility. It also simplifies disposal or recycling of the sensor array components after their use.

What role does the Freescale MPVZ5004GW6U sensor play in the 3D-printed sensor array, and what are its key specifications?

The Freescale MPVZ5004GW6U sensor is a key component of the 3D-printed sensor array, serving as a pressure sensor that detects underwater signals. Its specifications, including a measuring range of 0-3.92 kPa and a sensitivity of 1 V/kPa, make it well-suited for capturing subtle pressure changes in the underwater environment. These characteristics enable the sensor array to accurately detect and interpret hydrodynamic signals indicative of nearby objects. The sensor must be waterproof to work effectively.

How does 3D printing contribute to the customization and cost-effectiveness of underwater sensor array development?

3D printing significantly enhances the customization and cost-effectiveness of underwater sensor array development by allowing researchers to rapidly prototype and tailor sensor designs to specific research needs. Traditional methods of creating sensor arrays are often complex and costly, especially when customization is required. 3D printing streamlines this process, reducing material waste, labor costs, and enabling faster iterations and improvements. This agility accelerates the design and testing phases, making it easier to explore different configurations and materials such as polylactic acid (PLA).

Beyond environmental monitoring and marine archaeology, what other potential applications could benefit from advancements in 3D-printed underwater sensor arrays?

Beyond environmental monitoring and marine archaeology, advancements in 3D-printed underwater sensor arrays could revolutionize several other fields. These include infrastructure inspection (e.g., inspecting underwater pipelines or bridge supports), search and rescue operations (locating submerged objects or individuals), and defense applications (detecting underwater threats). The ability to accurately and cost-effectively locate objects underwater, facilitated by technologies like the Freescale MPVZ5004GW6U sensor integrated into a polylactic acid (PLA) 3D-printed structure, opens doors for innovation across diverse sectors, enhancing safety, efficiency, and our understanding of the underwater world.