APC Intern Creates Lasting Impacts through Additive Manufacturing at Austal USA

The Company

Headquartered in Australia, Austal is one of the largest shipbuilders in the world, producing passenger ferries, patrol boats, high-speed support vessels, surface combatants, and multi-role ships. Austal USA, which opened its Mobile, AL shipyard in 1999, has since grown into one of the city’s largest employers with roughly 4,000 employees. The site plays a critical role in building the Littoral Combat Ship (LCS) and Expeditionary Fast Transport (EPF) programs for the U.S. Navy.

The Solution

In the summer of 2019, Austal USA partnered with the Alabama Productivity Center (APC) to host University of Alabama senior mechanical engineering student, Thomas Mercier. Prior to the internship, Thomas had just completed a co-op with Johnson Controls in Geneva, AL, and he brought strong problem-solving skills to Austal’s operations.

Thomas led two impactful projects. The first involved collaborating with skilled workers to identify commonly used parts that were costly and time-consuming to order. Instead of purchasing these components for $30–$40 each, Thomas modeled them in CAD software and reproduced them through 3D printing for about $1 per part. The new process not only produced immediate savings but also created a digital library of designs that Austal employees can now access and reproduce on demand, delivering sustained long-term value.

In addition, Thomas evaluated products from sales representatives, compiled reports, and presented findings to Austal teams, helping the company make informed purchasing decisions that aligned with operational needs.

Through his projects, Thomas gained hands-on experience in additive manufacturing, an innovative process that builds 3D objects by layering materials such as plastic, metal, or concrete. His work demonstrated how emerging technologies can be applied in real-world settings to reduce costs and improve efficiency.

Measurable Impacts

-$80,000 in cost savings, with additional savings accumulating as his 3D designs are reused