Design of tomorrow’s marine engine covers

Abstract

This thesis explores the redesign of the D6 engine cover with the objectives of improving noise reduction, aesthetics, and durability. The primary motivation for the project was to achieve a measurable reduction in engine noise through modifications to the cover alone, without altering the engine itself. Additionally, the existing cover has remained unchanged for several years, highlighting an opportunity for design improvement. The project adopts a traditional design methodology based on sequential engineering, guiding the process from problem identification to concept generation and prototyping. A series of design concepts were developed and evaluated according to acoustic performance, visual appeal, and structural resilience. These concepts were iteratively refined, leading to the selection of one final design considered the most promising based on a combination of theoretical performance and practical feasibility. This final concept was further developed using CAD modeling tools and subsequently prototyped through 3D printing, enabling preliminary physical evaluation. Although the project resulted in a tangible prototype, the findings underline the need for continued research, particularly in advanced acoustic testing, material optimization, and long-term durability studies, to validate the design under realistic operating conditions. This work provides a foundation for future development and highlights the value of design-focused interventions in addressing performance and aesthetic challenges in marine engine components