Naval industry is stifled by the new demands for a larger surface fleet in a new age of strategic competition. Existing capacity simply cannot deliver new vessels while maintaining old ones at the point of need.
There are, however, two solutions to this dilemma which the US and UK navies have separately pursued in recent months. While the UK Royal Navy (RN) has resolved to cut down its fleet and implement a smaller forward-presence model, the US Navy has turned to new methods of ship maintenance.
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With the help of Gecko Robotics, a Pittsburgh-based small-to-medium sized enterprise, US Navy (USN) maintenance is overcoming the enduring inefficiencies of conventional ship maintenance.
Using robots topped with advanced sensors to scour hull structures, the company will use the data collected and processed by artificial intelligence (AI) to provide a high-fidelity digital twin representation known as a ‘rich asset model’. This constitutes Gecko’s Cantilever network of AI and Robotics, or ‘AIR’ solution.
“You’re continually managing and predicting all the damaged areas, and you can understand it from health report. Just like when you or I would go to a doctor to do a complete body scan,” explained Gecko’s co-founder and CEO, Jake Loosararian.
In an exclusive, Loosararian spoke to Naval Technology about the need to improve ship maintenance with these new tools, while overcoming the problematic incentives behind traditional maintenance procedures.
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Benefits in data
At present, the USN only has about two-thirds of its surface fleet available right now, Loosararian acknowledged. According to recent figures, as of September 2024, the service included 297 battle force ships in total; this would put nearly 100 ships either in maintenance or idle.
Moreover, the USN anticipate that this total ship count will decline by nine units in the next fiscal year 2025.
Gecko’s AIR network solution is a “game-changing way of approaching speeds and schedule adherence,” he emphasised, having supported dozens of USN surface vessels.
Their new methods cut labour by 85% in mapping hulls, and the USN indicated that their technology saved the service “more than four months of maintenance time.”
Current inefficiencies
Traditionally, engineers would do the work of Gecko’s robots in searching hulls for any signs of wear and tear or any defects and subsequently map them out.
In contrast, Gecko use high definition cameras to create photogrammetry. These point clouds (3D model of the structure) allow them to see different defects. From 30 metres out you can see these different weld lines and dents. This allows Gecko to pre-empt future problems ahead of time.
“There is bureaucracy and primes that are blocking this because it messes with the incentive models that currently exist that are good for large contractors.”
Jake Loosararian, Co-founder and CEO of Gecko Robotics.
Using the old methods, naval primes are “doing these cycles going on 18, 20, even 24 months,” Loosararian pointed out. “How do you predict and prevent this in the future? How do you create strategies to increase the lifespan of the asset? How do you avoid having some sort of cash-out failure?
“There is bureaucracy and primes that are blocking this because it messes with the incentive models that currently exist that are good for large contractors… It obviously hampers us in a lot of ways,” he added.
Countries like China, with whom the US are contesting in the Indo-Pacific region, are able to build much faster. “We are not able to do that,” he added, “we have to ensure that we modernise and improve the inefficiencies.”
UK fails to adapt
“It baffles me that the UK Royal Navy is not picking up on this right now because it solves an immediate and very important problem.”
Instead, the RN has started to double down on cuts at the end of November. The Defence Secretary, John Healey, ended the life of the Type 23 frigate HMS Northumberland and axed two Albion-class amphibious assault ships. The Ministry of Defence has since deployed fewer ships and sailors for a nimbler forward presence abroad.
Recently, the RN even considered deploying commercial ships in a multi-purpose capacity as “floating bases for certain operations.” This was suggested after SD Northern River – a commercial, offshore supply vessel – facilitated the trial of a prototype mine counter measure boat in Scotland this month.
Undaunted, Gecko Robotics is currently engaging with British defence primes to find a way to bring its offerings across the Atlantic. Early discussions have taken place with a number companies.
“The speed of maintenance has been unprecedented because of how clear the results are having in terms of an impact – a huge impact – on the most important problem right now for the Navy and for navies all around the world.”
