Use 3D-printed housings for deep-sea exploration at depths of thousands of meters.

Posted by FIT THAI on August 4, 2026

The ocean covers more than 70% of the Earth’s surface, yet the US National Oceanic and Atmospheric Administration (NOAA) estimates that less than 20% of it has been explored. Compared to the scale and advancements in space exploration, ocean exploration remains severely underfunded and underappreciated. Despite these challenges, some researchers persevere, turning their attention to accessible 3D printing technology to find ways to dive deeper.

At the Underwater Robotics and Imaging Laboratory, located at the University of Rhode Island’s Bay Campus, Professor Brennan Phillips and his students are building tools that can explore areas thousands of meters beneath the ocean's surface. The lab uses Form 3+ and Form 3L stereolithography (SLA) 3D printers to print waterproof camera housings and various research tools.

Pressure-Resistant Waterproof Parts

Mapping the ocean requires instruments that are not only waterproof but also capable of withstanding the immense pressures at the seabed. Phillips and his students began designing 3D printed camera housings. After dozens of iterations and refinements, the team decided to print the cylindrical housing in two pieces using Clear Resin on a Form 3+. Inside the housing is a circuit board, and epoxy resin is used to secure the camera lens in a floating position. The entire area beneath the lens is filled with epoxy resin, injected through a channel designed as part of the housing.

“The challenge was, what’s the smallest and cheapest deep-sea camera? We're now printing dozens of cameras in different shapes, and we can make them in any shape. We can design them quickly, assemble the electronics, scale them appropriately, and then pour in the epoxy resin,” Phillips said.

Thanks to 3D printing, the lab can prototype and test iterations without worrying about exceeding their budget. It also allows for the creation of designs that would be impossible to achieve with traditional machining processes, offering greater design flexibility.

The DEEPi camera design uses a hybrid approach combining 3D printed molds and O-ring seals, with space for epoxy resin to encapsulate circuit board components and an external viewing port made of clear glass (U.S. Patent No. 16/920,577).

Inside the lab, pressure tanks are used to simulate deep-sea conditions. Once Phillips and his students settled on a two-part design using epoxy resin, they placed the part in a pressure tank and increased the pressure to simulate actual deep-sea environments.

“It's a full-fledged experiment, but once we started deploying the cameras, they went much further than we ever anticipated, thousands of meters deep,” Phillips said.

Why SLA is ideal for deep-sea robotics

When Phillips' lab evaluated various 3D printers, accuracy and material properties were top priorities.

The isotropic nature of SLA printed parts means they have no porous structure and do not suffer from water leakage issues like parts printed with fused deposition modeling (FDM) technology.

Additionally, the smooth surface of SLA parts allows for precise assembly of functional components, such as the two-part cylindrical housing, without gaps caused by rough surfaces.

With very tight tolerances and the ability to create small details, users can print threads directly onto the material. Phillips' lab uses this method for two-part housings and screws to enhance security.

The 3D printed pressure housing assembly, a finished part capable of protecting electronics from seawater at depths greater than 1,000 meters. O-rings are printed directly on the part, and the housing is sealed with a hand-tightened bezel ring.

Phillips said, “With FDM, even if you can get an IP rating, it can't withstand pressures of several meters. Next, you need the resolution for the O-ring between the two parts to seal perfectly. By lightly sanding the 3D printed parts to smooth critical surfaces, a perfect seal can be achieved.”

Phillips also stated, “The third reason is that the material properties of SLA are excellent. In terms of yield strength, it's vastly superior. All elastic moduli are better than other materials.”

Thanks to the precision of Formlabs printers and material accessibility, the lab's core work—deep-sea waterproof housings—can be developed and used both on land and at sea. In January 2020, Phillips and his students published a 3D printing process using "Form 2" stabilization kits. They were able to print identical housings with no measurable difference compared to parts printed on land, meaning these devices can be printed and deployed on ships worldwide, on-site. This research advances the lab's mission to democratize deep-sea science and proves that these essential tools can be produced locally at low cost.

Integrating the Form 3L

When Formlabs announced the Form 3L, Phillips and his lab were quick to adopt it. “We were among the first to use the Form 3L. Its large build volume allows for experimenting with larger underwater designs and enhances other lab operations with more innovative research tools.”

To deploy these housings and other sensors underwater, the lab needed to use and manage thousands of feet of delicate fiber optic cable. To prevent tangling and knotting, they started by repurposing bicycle wheels to guide the fiber optic cable from the side of the ship. With the Form 3L, they could prototype designs to miniaturize and optimize this process.

3D printed "slides" help guide fiber optic cables smoothly along the side of the ship, preventing tangles or breaks.

Phillips said, “In the case of this monofilament line, we didn't want to use a spinning reel or spool. We wanted a slide. So we iterated this slide about three or four times. It's large, smooth, and that smoothness is beneficial for very thin fibers.” The slides, made with Clear Resin, reduced the time required for careful cable retrieval and reuse, and decreased the frequency of equipment replacement.

Fiber Optic Innovation

Fishing line, though requiring effort to reel in, is not a very delicate material. However, fiber optic cables cannot be handled the same way and are much more expensive if damaged. Phillips' lab collaborated with Nautilus Defense LLC in Pawtucket, Rhode Island, to develop a new type of fiber optic fishing line called FOFL (U.S. patent pending).

Phillips said, “If you use fiber optics, you can do many things like Ethernet or live video. Long-distance connections with copper wire are very difficult. Fiber optic fishing line is something that has never existed before.”

Since fiber optic cables cannot be tied or handled like other durable ropes, the lab needed to invent a device for securing the cable ends.

Using 3D printed parts with very tight tolerances, achievable with Formlabs' high-resolution SLA printers, they could separate the load-bearing outer braid of the line from the fragile fiber optic core. The fiber optic is secured to a 3D printed holder with injected epoxy resin, then passed through a metal furcation tube, and connected to a computer to receive data transmitted by the fiber optic.

SLA printed parts are used as the mechanical termination of the "Fiber Optic Fishing Line" (FOFL), which is U.S. patent pending, to separate the load-bearing outer braid from the delicate fiber optic core.

Phillips said, “This type of connector is very strong and can support at least 100 pounds. We have applied for a patent and also made the design open source.”

Phillips also said, “If using conventional manufacturing processes, it would cost $3,000 to $4,000 each time, and without a 3D printer, it would be difficult to conduct multiple tests and iterations. I don't think anyone has done this before because the path to manufacturing was too expensive. The combination of rapid prototyping methods like Formlabs printers and new fiber optic cables allows for such novel ideas to emerge.”

Cost-Effective 3D Printed O-Ring Seals

Before 3D printing, developing these tools was costly. Researchers couldn't modify designs as needed, and underfunded projects couldn't proceed with development.

The Underwater Robotics and Imaging Laboratory is part of a global movement called "Deep and Cheap," an effort to democratize science, provide access to these technologies, and deepen our understanding of the oceans around us.

Phillips said, “I started 3D printing end caps with integrated O-rings, and it worked. If this part had to be machined, it would cost hundreds to thousands of dollars and require very detailed blueprints. But with this printer, we can print three or four pieces, then create one that fits perfectly, for a material cost of only about $50.”

The research team is not limited to producing functional parts but has also created a workflow for printing molds with Clear Resin. Ultimately, using 3D printed molds became the most suitable method for quickly connecting underwater cables.

Diverse Applications

Within Phillips' laboratory, Formlabs printers are used for prototyping, end-product manufacturing, rapid tooling, creating jigs and fixtures, and even producing medical devices.

Despite being a small laboratory, thanks to the innovative ideas of Phillips and his students, the scope of applications and new opportunities continues to expand.

During the COVID-19 pandemic, Phillips and his students realized they had the capacity to make a real difference in Rhode Island's pandemic response.

Through extensive testing and thorough research, the lab published verification results for chemical emissions from Formlabs Surgical Guide Resin, used for 3D printed ventilator parts.

In addition to publishing scientific data, they successfully submitted applications to the U.S. Food and Drug Administration (FDA) and for Emergency Use Authorization (EUA).

Phillips said, “During the pandemic, there were many efforts from large manufacturers, but we wanted to help in the most effective way possible. With the quality of this printer and the availability of Surgical Guide Resin, we were able to contribute and help at a higher level.”

The "Y-splitter" part for ventilators, designed in collaboration with researchers from Brown University and Rhode Island Hospital, was 3D printed using Surgical Guide Resin during the early stages of the COVID-19 pandemic.

Democratizing Deep-Sea Exploration

The low cost of producing these parts not only benefits the lab's budget but also means that students are not restricted from accessing these machines for learning, including experimenting with new ideas that might fail.

Undergraduate students designing parts for the first time can access this technology and learn 3D printing without fear that their mistakes will waste valuable resources.

Each year, URI sophomores have the opportunity to design and 3D print pressure housings, allowing them to participate in research while learning valuable new skills in CAD and 3D printing.

Phillips said, “Before this 3D printer, students wouldn't have designed or built their own underwater housings until graduate school or entering industry and receiving all their training. But this printer has opened doors for them. I've had high school students build pressure vessels.”

Phillips is also a member of an international community dedicated to improving access to and reducing the cost of deep-sea exploration tools in underdeveloped coastal nations worldwide.

Phillips said, “We are working on capacity building for countries that want to conduct their own deep-sea exploration. These methods have the potential to make deep-sea exploration more accessible.”