Introduction to Southern Ocean Subsea. Pioneering Australian Technology
SoSub is a pioneering Australian technology company that designs and delivers advanced subsea solutions for the aquaculture, marine, and defense industries. Headquartered in Tasmania, with operations in Victoria, SoSub is known for developing robust underwater systems that streamline operations, improve safety, and support sustainable aquaculture practices. From remotely operated vehicles (ROVs) to automated net repair systems, their innovations are transforming how underwater tasks are performed across Australia and beyond.
At the heart of SoSub’s success is their flagship APAMA technology platform, which includes tools like the APAMA NRS (Net Repair System) and APAMA ROV. These cutting-edge solutions remove the need for human divers in hazardous environments and offer precision control in underwater inspection, maintenance, and repair. Their systems are purpose-built to withstand the challenging conditions of aquaculture environments, helping operators improve uptime, reduce risk, and increase operational efficiency.
Beyond technology development, SoSub is deeply invested in collaboration and continuous improvement. They work closely with industry partners like Huon Aquaculture, and contribute to national innovation efforts, including programs supported by the Australian Government Entrepreneur Program. SoSub also shares insights through regular blogs and case studies, reinforcing their commitment to transparency, knowledge sharing, and pushing the boundaries of subsea innovation. Learn more at SoSub.com.au.
Into the Depths: The Challenge of Underwater Innovation
The nature of SoSub’s operations presents a host of engineering challenges. ROVs must operate in underwater environments where pressures can reach extreme levels, placing enormous stress on each component. Every part must be engineered with precision and made from materials that can handle corrosion, pressure, and impact.
SoSub faced several key challenges:
- Harsh Environmental Demands: Components had to survive depths of several hundred meters or more, meaning the materials needed to be both strong and resistant to water ingress and deformation.
- Long Iteration Cycles: Traditional manufacturing of custom parts involved long lead times, often taking days or weeks for outsourced components to be delivered and tested.
- High Cost of Low-Volume Manufacturing: Producing small batches or single parts was expensive and inefficient using conventional fabrication methods.
- Decentralized Teams and Global Projects: SoSub operates on a global scale with international collaborations. They needed a way to produce the same part in multiple locations with exact precision and consistency.
To stay agile, reduce prototyping timelines, and maintain control over the quality of mission-critical parts, SoSub required a versatile in-house manufacturing system capable of producing high-quality components quickly and reliably.
Finding the Right Solution
To solve these challenges, SoSub partnered with Thinglab, seeking guidance on the best technology to meet their demanding requirements. With deep knowledge of the additive manufacturing landscape, Thinglab understood that SoSub needed more than just a machine—they needed a scalable, high-performance system with robust materials and reliable support.
Following a detailed assessment, Thinglab recommended the Formlabs ecosystem of professional 3D printers.
This solution delivered on every front. Formlabs printers offered the industrial-grade print quality that SoSub demanded. With access to a broad library of engineering resins, SoSub could produce parts with properties tailored to deep-sea conditions—from high-temperature resistance to toughness and rigidity. Remote print management made it easy for their global teams to collaborate and produce consistent parts no matter where they were based.
“We designed it, got it up and running, and pressure-tested it to depth—all within two days.”
And with Thinglab’s technical support on standby, SoSub had confidence their system would run smoothly and efficiently, even during mission-critical development cycles.
Implementation & Support
Thinglab didn’t just supply a printer and walk away. They helped SoSub set up a fully integrated in-house manufacturing solution.
Installation began with the delivery and configuration of Formlabs 3D printing and post-processing stations, strategically designed to fit into SoSub’s existing workspace and workflow. Training followed soon after, tailored to SoSub’s engineering teams, covering every step from material selection and print setup to part finishing and quality assurance.
Thinglab also worked closely with SoSub to streamline their production workflows. Together, they developed print management practices and integrated 3D printing into the company’s CAD design pipeline. Standard operating procedures were established to ensure consistency and repeatability, while Thinglab remained available for remote troubleshooting and advice as new materials or production needs arose.
Thanks to this hands-on support, SoSub was up and running quickly, producing functional ROV components with remarkable turnaround times.
Results & Benefits
The results were immediate and impressive. SoSub was no longer waiting on outsourced parts—they were manufacturing them in-house, often in a matter of hours using Formlabs to power their 3D printing department.
“The new printers are exceptionally good because they print so much quicker ”
Prototyping became dramatically faster. Engineers could test multiple designs in a single day, accelerating innovation and reducing the risk of costly errors by utilising 3D printing. Many of the parts produced weren’t just prototypes—they were mission-ready, used directly on SoSub’s underwater vehicles with complete confidence in their durability and performance.
The choice of engineering resins played a major role here. Tough 2000, High Temp, and Rigid 10K allowed SoSub to tailor parts for specific mechanical and environmental demands. These materials handled the punishing pressures of deep-sea conditions without cracking or warping.
Remote print capabilities further enhanced efficiency. SoSub’s teams, whether in Australia or abroad, could prepare, queue, and monitor prints from any location. This reduced logistics complexity and ensured consistent quality across projects.
The financial benefits were equally significant. In-house production eliminated outsourcing fees, reduced lead times, and gave SoSub the flexibility to produce single units or small batches cost-effectively. Engineers had greater control over their workflows, making real-time adjustments without delays or dependency on third parties.
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Looking Forward
With a proven system in place, SoSub is already planning the next phase of their additive manufacturing journey.
They’re looking to scale up their print capacity, expanding their fleet of Formlabs printers to meet growing production demands. There’s also interest in exploring new 3D printing materials as Formlabs continues to innovate—resins with enhanced thermal resistance, chemical durability, or flexibility could open up even more applications.
Beyond material science, SoSub sees potential in combining additive manufacturing with CNC machining and robotic automation to create a hybrid production model. And by building a digital library of standard parts, they aim to enable on-demand manufacturing for future missions—wherever and whenever components are needed.
Thinglab remains a trusted partner, providing advice, technical support, and the expertise needed to keep SoSub at the forefront of subsea innovation.
Conclusion
The partnership between SoSub and Thinglab is a testament to the power of expert collaboration and cutting-edge technology.
By implementing Formlabs 3D printing solutions, SoSub has transformed its approach to design and manufacturing. The result is a faster, more agile production workflow, with custom components that are strong enough for the ocean’s depths and precise enough for complex engineering systems.
This case study is more than just a story of successful technology adoption—it’s a glimpse into the future of rapid manufacturing, where innovation happens on-site, on-demand, and on time. With Thinglab’s guidance and Formlabs’ robust tools, SoSub has redefined what’s possible beneath the waves.
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