A closed-loop engineering framework for rapid development of unmanned maritime systems using integrated digital and additive technologies

This study presents a closed-loop engineering methodology for the rapid development of unmanned maritime systems by integrating 3D scanning, reverse engineering, digital optimization, additive manufacturing, subsystem
integration, and experimental validation within a unified feedback-driven workflow. Unlike existing manufacturing-oriented closed-loop and digital twin approaches, the proposed methodology connects the complete engineering lifecycle through continuous interaction between digital models and physical prototypes. The methodology was validated through two complementary case studies representing reverse and forwardengineering development scenarios: a modular UAV platform and a coastal monitoring buoy. Comparative engineering workflow assessment indicated an estimated 30–50% reduction in overall prototype development effort and a 35–40% reduction in component-level redesign activity, while ICP-based evaluation of selected representative UAV components showed maximum geometric deviations of 0.5–1.5 mm. Functional validation further confirmed subsystem operation and structural performance under the investigated test conditions. The proposed methodology extends feedback beyond manufacturing-stage optimization to the complete engineering lifecycle, providing an adaptable engineering approach for rapid prototyping, iterative engineering refinement, and modular development of unmanned maritime systems and related cyber-physical engineering applications.