DEEP Installs WAAM-Built Subsea Habitat in Florida Keys

DEEP, a company focused on Wire Arc Additive Manufacturing (WAAM), has completed the installation of its pilot subsea human habitat, Vanguard, on the seafloor at Tennessee Reef within the Florida Keys National Marine Sanctuary. The habitat's components were manufactured using WAAM technology, following a complex marine operation that secured the system to the ocean floor.

This WAAM approach was adopted due to pandemic-era supply chain disruptions, leading to the establishment of DEEP Manufacturing, a subsidiary that has since been spun off. The completed habitat now rests at a depth of 17 meters (56 ft). Its livable section measures 10.7 meters (35 ft) long and 2.5 meters (8 ft) wide, designed to accommodate up to four aquanauts for missions lasting five days or more. The installation process involved creating an ocean floor foundation, attaching the habitat, and tethering a surface support buoy.

Sea acceptance testing and commissioning are currently in progress, with DNV providing independent technical assurance throughout the design and build phases. DEEP plans to proceed with crew training before Vanguard commences its first research missions. This pilot habitat is the initial phase of a larger program, intended to inform the development of Sentinel, a more extensive, modular habitat system.

DEEP Manufacturing has achieved significant milestones in WAAM production, including securing full DNV Approval of Manufacture for pressure vessels, hull structures, and equipment in October 2025. This approval signifies the company's readiness to produce large, safety-critical WAAM components to stringent standards. Further expansion of their Houston facility in March 2026, part of a $10 million investment, aims to bring large-scale metal additive manufacturing closer to energy, defense, and maritime sectors.