Table of Contents
- Executive Summary: The 2025 State of Underwater Drone Welding
- Market Size & Forecast: Growth Projections Through 2028
- Key Players and Industry Leaders: OEMs, Innovators, and Partnerships
- Core Technologies: AI, Robotics, and Welding Automation Underwater
- Applications: Offshore Oil & Gas, Renewable Energy, and Shipbuilding
- Regulatory and Safety Standards: Compliance and Certification Update
- Challenges: Technical Barriers and Environmental Considerations
- Investment and Funding Landscape: Where Capital Is Flowing
- Case Studies: Recent Deployments by Leading Manufacturers
- Future Outlook: Emerging Trends and Competitive Strategies
- Sources & References
Executive Summary: The 2025 State of Underwater Drone Welding
In 2025, underwater drone welding technology has reached a pivotal point, transitioning from experimental trials to active deployment in commercial and industrial settings. Driven by the increasing demands of offshore energy, shipbuilding, and critical infrastructure maintenance, remotely operated vehicles (ROVs) and autonomous underwater vehicles (AUVs) equipped for welding are now shaping the subsea repair and construction landscape.
Recent advancements have been spearheaded by industry leaders such as Saab and Oceaneering International, who have integrated high-precision welding tools into their ROV platforms. These systems now feature advanced manipulators, real-time imaging, and improved haptic feedback, enabling remotely operated welding tasks at depths exceeding 1,000 meters. In 2025, Saab announced new upgrades to its Seaeye series, specifically targeting subsea fabrication and repair, with in-situ testing already underway at North Sea oil platforms.
A significant milestone was achieved in early 2025 when Oceaneering International publicly demonstrated a fully automated subsea welding procedure performed by their Freedom AUV, addressing a live corrosion patch on a subsea pipeline. The operation, conducted in partnership with leading energy companies, achieved weld integrity standards comparable to traditional diver-based processes, signaling a shift towards increased automation and safety in subsea operations.
Meanwhile, technology firms such as FANUC and KUKA are collaborating with marine contractors to adapt industrial robotic welding arms for underwater environments, addressing challenges related to pressure, salinity, and remote operation precision. These collaborations are yielding new underwater-rated actuators and sensor suites, supporting the next generation of welding-capable drones.
Looking ahead, the underwater drone welding market is expected to continue its rapid growth through 2027, propelled by the need to extend the lifespan of subsea assets and the global push for safer, more sustainable offshore operations. Industry bodies such as DNV are actively working on updating certification and safety standards to accommodate robotic and autonomous welding technologies, further legitimizing their role in critical infrastructure.
In summary, 2025 marks a breakthrough year for underwater drone welding, with real-world deployments, validated performance, and ongoing technology integration setting the stage for broader adoption in the coming years.
Market Size & Forecast: Growth Projections Through 2028
The underwater drone welding technology market is experiencing notable growth in 2025, as offshore infrastructure, shipbuilding, and subsea pipeline projects increasingly demand automated solutions for inspection, maintenance, and repair. The integration of advanced robotics and remote operation capabilities is enabling significant expansion in both the range and complexity of underwater welding tasks, previously limited by diver safety and accessibility constraints.
Recent milestones include the deployment of several pilot projects and the commercialization of remotely operated vehicle (ROV)-based welding systems. For example, Saab has expanded its underwater robotic offerings to include multi-mission ROVs capable of supporting welding tools, while Oceaneering International, Inc. is advancing ROV platforms designed for complex subsea intervention, including hot-tap welding and pipeline repair. Fugro has also reported new contracts for ROV-supported subsea construction and maintenance, reflecting a rising demand for autonomous and remotely piloted welding solutions.
The global push for renewable offshore energy—especially wind and tidal—along with aging subsea oil and gas assets, is expected to fuel further adoption. Industry estimates and company statements suggest high single-digit annual growth rates through 2028. For instance, Saab projects rising demand for its hybrid AUV/ROV systems, specifically citing subsea asset integrity and welding as growth drivers in its 2024-2025 investor updates. Similarly, Oceaneering International, Inc. has publicly highlighted the subsea robotics sector as a core area of expansion through 2028, underpinned by increased demand for automated welding and repair in deepwater environments.
- Key growth factors: expanding offshore energy infrastructure, the need for cost-effective maintenance of pipelines and subsea structures, and increasing safety/environmental regulations driving automation.
- Technology outlook: Ongoing innovations in sensor integration, high-precision manipulator arms, and AI-driven navigation are expected to enable more complex underwater welding tasks, including in deeper and harsher environments.
- Regional trends: North America and Europe currently dominate deployment, but Asia-Pacific—especially China and Southeast Asia—shows rapid uptake due to large-scale offshore projects.
By 2028, the underwater drone welding sector is forecast to transition from pilot and semi-automated deployments to broader commercial adoption, with leading suppliers like Saab, Oceaneering International, Inc., and Fugro poised to capture expanding market share as operator confidence and regulatory acceptance increase.
Key Players and Industry Leaders: OEMs, Innovators, and Partnerships
The underwater drone welding technology sector in 2025 is marked by a convergence of established Original Equipment Manufacturers (OEMs), emerging innovators, and a growing number of strategic partnerships. This collaborative ecosystem is driving advances in both remotely operated vehicles (ROVs) and autonomous underwater vehicles (AUVs) equipped for subsea welding tasks, enabling safer and more efficient maintenance of offshore infrastructure.
Among OEMs, Saab AB continues to be a key player, leveraging its established ROV platforms—such as the Seaeye range—to integrate advanced manipulation and welding modules. These systems are increasingly adopted by energy majors for subsea intervention and repair, enabling remote welds at significant depths while minimizing human diver exposure.
Innovation is also driven by companies like Sonardyne International Ltd., which specializes in subsea robotics and positioning systems. Their technology underpins precise control and navigation for welding drones, facilitating complex operations such as pipeline and structural repairs in challenging underwater environments.
A notable recent development is the partnership between Oceaneering International, Inc. and major offshore operators. By integrating proprietary ROVs with specialized welding equipment, these collaborations have resulted in successful pilot projects for live subsea pipeline repairs, particularly in the North Sea and Gulf of Mexico. The company’s Magellan ROV platform, combined with its advanced tooling, has demonstrated the ability to perform automated welds at depths exceeding 1,000 meters.
Emerging innovators such as Kongsberg Maritime are advancing the field through their Maritime Robotics division, which is developing modular AUVs with enhanced dexterity and AI-driven control for adaptive welding processes. These innovations are aimed at enabling fully autonomous subsea repairs, reducing reliance on surface vessels and operators.
Industry bodies like DNV play a crucial role in setting standards and certifying new underwater welding technologies. In 2024–2025, DNV introduced updated guidelines for robotic in-situ welding, accelerating commercial acceptance and deployment of these solutions.
- OEMs such as Saab AB and Kongsberg Maritime are investing in next-generation ROV/AUV platforms with integrated welding capabilities.
- Strategic partnerships—exemplified by Oceaneering International, Inc.—are expediting real-world deployments and scaling of underwater drone welding solutions.
- Standardization efforts led by DNV are fostering wider industry adoption, with new certifications expected to catalyze further growth through 2026 and beyond.
As the sector matures, collaboration among OEMs, innovative start-ups, and standards organizations is expected to accelerate, with expanded field trials and commercial projects anticipated to define the underwater drone welding landscape in the coming years.
Core Technologies: AI, Robotics, and Welding Automation Underwater
The rapid advancement of underwater drone welding technology in 2025 is being propelled by the integration of artificial intelligence (AI), sophisticated robotics, and advanced welding automation. These technologies are converging to address the significant challenges posed by subsea environments, such as limited visibility, high pressure, and complex geometries of underwater structures.
AI-powered systems are enhancing the operational efficiency and safety of underwater welding by enabling real-time decision-making and adaptive process control. Modern underwater drones, or remotely operated vehicles (ROVs), are now equipped with machine learning algorithms that can optimize welding parameters, detect and adapt to anomalies, and autonomously plan welding paths. Saab, for example, has incorporated advanced control systems into its Seaeye Falcon ROVs that allow for precise maneuvering and manipulation during complex maintenance and repair operations.
Robotic manipulators specifically designed for subsea welding have also seen significant progress. These manipulators, integrated into ROVs or autonomous underwater vehicles (AUVs), offer multi-axis dexterity and the ability to use a variety of welding processes such as wet shielded metal arc welding (SMAW) and friction stir welding. TechnipFMC has been actively deploying ROV-based robotic arms for pipeline repair and maintenance, leveraging automated welding heads that can maintain consistent weld quality even in turbulent conditions.
Automation is further supported by advanced sensors and real-time monitoring systems. These include high-definition cameras, ultrasonic sensors for weld inspection, and environmental monitoring units that feed data to AI-based supervisory systems. The integration of such sensors is evident in the solutions offered by Oceaneering International, Inc., whose ROVs can perform not only welds but also non-destructive testing (NDT) immediately after, reducing downtime and ensuring integrity.
Looking ahead, the next few years will likely see broader deployment of hybrid AI-robotic welding units capable of more autonomous operation, especially for deepwater energy infrastructure and offshore wind installations. As AI models become more sophisticated, there is an industry-wide push towards “digital twin” environments that simulate underwater welding scenarios, further improving the planning and execution of complex subsea repairs (Kongsberg Maritime). The continued collaboration between ROV manufacturers, energy operators, and digital solution providers will be crucial for scaling underwater drone welding technology, with the potential to reduce operational costs, improve safety, and extend asset lifespans in challenging subsea environments.
Applications: Offshore Oil & Gas, Renewable Energy, and Shipbuilding
Underwater drone welding technology is rapidly transforming key sectors such as offshore oil & gas, renewable energy, and shipbuilding. As of 2025, these industries are increasingly integrating remotely operated vehicles (ROVs) and autonomous underwater vehicles (AUVs) equipped with advanced welding systems to address complex maintenance and construction challenges in subsea environments.
In the offshore oil & gas sector, underwater infrastructure such as pipelines, risers, and subsea manifolds demand frequent inspection and repair. Traditionally, these tasks required costly and hazardous human diver intervention. Recent advancements in underwater drone welding, led by companies like Saab and Oceaneering International, have enabled remotely controlled or semi-autonomous robots to perform high-precision weld repairs at depths and durations beyond human capability. For example, Saab’s Seaeye ROVs are now being adapted with modular toolkits for in-situ welding and cutting, streamlining urgent repairs and minimizing production downtime. The ability to deploy these systems in deepwater fields is expected to accelerate as subsea asset aging and expansion of offshore projects continue through 2025 and beyond.
The renewable energy sector, especially offshore wind, is another key beneficiary. Foundations, monopiles, and inter-array cables require robust welding solutions during installation and ongoing maintenance. Companies such as Fugro are integrating ROV welding capabilities to support wind farm construction, reducing vessel time and improving safety. These systems are increasingly used for attaching anodes, repairing corrosion, and retrofitting cable protection devices—all critical as Europe and Asia ramp up offshore wind capacity targets through the late 2020s.
Shipbuilding and repair yards are also adopting underwater drone welding to maintain and upgrade vessels without extensive drydocking. DeepOcean is working with partners to trial underwater drone welding for hull repairs and retrofits, enabling faster turnaround and reduced operational disruption. As international shipping regulations tighten on hull integrity and emissions, robotic underwater welders are expected to play a crucial role in compliance and lifecycle management.
Looking forward, the outlook for underwater drone welding is highly positive. Ongoing R&D by industry leaders and organizations such as DNV is focused on improving weld quality monitoring, remote process control, and integration with digital twin systems. With the push for safer, more efficient, and lower-emission operations across the maritime and energy industries, the adoption and sophistication of underwater drone welding technology are set to expand significantly over the next few years.
Regulatory and Safety Standards: Compliance and Certification Update
The rapid advancement of underwater drone welding technology in 2025 is prompting significant updates to regulatory and safety standards, with a focus on ensuring the safe integration of remotely operated and autonomous welding systems in subsea environments. As underwater drones become increasingly capable of performing complex welding tasks at depth, regulatory bodies and industry leaders are working to adapt and harmonize existing standards, while also developing new certification pathways tailored to robotic and autonomous underwater operations.
In 2025, the DNV (Det Norske Veritas) remains at the forefront of standardization for underwater welding, having updated its offshore welding guidelines (DNVGL-OS-C401) to include provisions for remotely operated and automated systems. These updates address critical aspects such as operational safety, equipment maintenance, remote monitoring protocols, and emergency intervention procedures. Notably, DNV’s guidelines now require rigorous risk assessments and failure mode analysis specific to the use of underwater drones for welding, emphasizing the need for redundancy in control systems and real-time data transmission to surface operators.
The American Welding Society (AWS) is also actively revising its underwater welding codes (AWS D3.6M), incorporating input from manufacturers and operators of underwater drones. In 2025, the AWS is piloting a certification program for operators and technicians supervising robotic welding operations subsea, combining traditional welder qualifications with training in human-machine interface management, remote diagnostics, and cybersecurity protocols for underwater systems.
Meanwhile, the International Marine Contractors Association (IMCA) has issued updated safety recommendations for the deployment of underwater drones in welding applications, particularly in the oil and gas and offshore wind sectors. IMCA’s 2025 guidance emphasizes the importance of real-time environmental monitoring—such as current, temperature, and visibility sensors integrated into drone platforms—to ensure welding integrity and operator safety. Additionally, IMCA is collaborating with drone manufacturers to develop standardized checklists and pre-mission validation protocols to minimize operational risks.
Manufacturers like Saab, a leading provider of underwater robotics, and Oceaneering International, which operates fleets of remotely operated vehicles (ROVs) for subsea construction, are aligning their system designs with these evolving standards. Both companies are investing in compliance testing and third-party certification of their welding-capable drones, aiming for broader acceptance in regulated markets. Looking ahead, further harmonization of international standards is expected, particularly with the increasing cross-border nature of subsea infrastructure projects.
In summary, 2025 marks a pivotal year for regulatory and safety standards in underwater drone welding technology, with leading industry bodies and manufacturers collaborating to ensure that compliance and certification keep pace with technological innovation. These efforts are expected to accelerate the adoption of underwater drone welding for critical subsea repairs and construction in the years ahead.
Challenges: Technical Barriers and Environmental Considerations
Underwater drone welding technology, poised for broader adoption in 2025, faces a set of complex technical and environmental challenges that must be addressed for successful deployment across sectors such as offshore energy, shipbuilding, and underwater infrastructure maintenance. The primary technical barriers stem from the integration of welding systems with remotely operated vehicles (ROVs) and autonomous underwater vehicles (AUVs), which must operate reliably in high-pressure, low-visibility, and corrosive marine environments.
A major technical hurdle is the stability and precision required for welding operations underwater. The hydrodynamic forces, variable currents, and need for fine manipulator control make it difficult to achieve consistent weld quality. Companies such as Saab and Oceaneering International, leading providers of ROVs, have developed sophisticated stabilization and feedback systems, but integrating advanced welding end-effectors remains challenging. Maintaining arc stability, especially for techniques like friction stir or hyperbaric arc welding, is further complicated by water conductivity and pressure, which can affect heat transfer and weld pool behavior.
Another technical barrier involves the power supply and control signal transmission to the welding apparatus. Underwater environments limit the use of traditional wireless transmissions, requiring robust tethered solutions or the development of reliable underwater communication protocols. For example, Kongsberg Maritime is researching advanced power management and data communication systems for subsea robotics, but the specific demands of welding—such as high current requirements and real-time process monitoring—add layers of complexity.
Environmental considerations are equally pressing. Underwater welding, especially when conducted by drones, can produce localized heating and the release of metal particulates or gases, potentially impacting marine ecosystems. Regulatory oversight is increasing, with organizations such as DNV and American Bureau of Shipping (ABS) setting standards for underwater operations to minimize ecological disturbance and ensure the safety of critical infrastructure.
Looking ahead into the next few years, the industry is focusing on developing closed-loop control systems, improved insulation and shielding for welding arcs, and environmentally benign consumables to mitigate these challenges. Collaborative projects between ROV manufacturers, welding technology companies, and class societies are expected to accelerate technical advancements and the establishment of best practices, balancing operational efficiency with environmental stewardship.
Investment and Funding Landscape: Where Capital Is Flowing
The investment and funding landscape for underwater drone welding technology in 2025 reflects a rapidly evolving sector attracting significant capital from both strategic industry players and venture capital. As offshore infrastructure—including oil & gas rigs, wind farms, and subsea pipelines—ages and expands, the demand for advanced maintenance solutions like remotely operated and autonomous welding drones has grown, prompting increased investment activity.
One of the notable recent developments is the continued backing of established marine robotics firms by major energy companies. For example, Saipem has been advancing its Hydrone robotic platform, which is capable of subsea intervention and, increasingly, complex repair tasks such as welding. Saipem’s robotics division has benefited from capital injections as part of broader digitalization and automation investments by European oil and gas operators looking to reduce downtime and operational risks.
In parallel, startups focused on underwater robotics are seeing increased interest from technology-focused venture capital funds as well as corporate venture arms of large offshore engineering firms. Ocean Infinity has raised substantial funding rounds since 2022 to further develop its Armada fleet of autonomous underwater vehicles, which are being fitted with modular payloads for tasks including subsea inspection and repair, paving the way for welding modules. The company recently announced additional funding in early 2025 to accelerate deployment of these advanced capabilities in the North Sea and Gulf of Mexico.
Meanwhile, major subsea technology suppliers such as TechnipFMC and Schilling Robotics (a division of TechnipFMC) are allocating significant internal R&D budgets toward underwater robotic welding systems, with an emphasis on integrating AI-driven controls and real-time monitoring for safety and precision. These investments are often matched by funding partnerships with offshore wind farm developers, particularly in Europe and East Asia, where underwater infrastructure expansion is most robust.
Looking ahead, the market outlook for funding in underwater drone welding technology remains strong for the next few years, driven by regulatory pressure for safer, more environmentally friendly subsea operations and the need to extend the life of existing marine assets. Strategic collaborations—such as joint technology development agreements—are expected to become more prominent, with funding increasingly targeting not just hardware innovation but also software and data analytics solutions to optimize underwater welding efficiency and traceability.
Case Studies: Recent Deployments by Leading Manufacturers
In recent years, the deployment of underwater drone welding technology has accelerated, with several leading manufacturers showcasing successful case studies across offshore infrastructure, shipbuilding, and energy sectors. These deployments in 2025 highlight the growing maturity of remotely operated welding systems, driven by the need for safer, more efficient, and cost-effective underwater maintenance and construction.
- Saab: In early 2025, Saab extended its Seaeye Sabertooth line with a specialized ROV (Remotely Operated Vehicle) equipped for hyperbaric welding. The Sabertooth drone performed automated weld repairs on subsea pipeline joints in the North Sea, achieving a 25% reduction in downtime compared to traditional diver-led operations. Saab reported that the mission was completed safely without diver intervention, demonstrating the platform’s capability for precision welding at depths exceeding 300 meters.
- Oceaneering International: In the Gulf of Mexico, Oceaneering International deployed its Millennium ROV for on-site pipeline welding and inspection. The project, conducted in partnership with a major energy operator, involved the use of adaptive welding arms and in-situ monitoring sensors. Oceaneering highlighted a significant improvement in weld quality consistency, reporting a 30% reduction in rework rates compared to previous manual techniques. The drone’s real-time data transmission enabled engineers to monitor and adjust welding parameters remotely, ensuring compliance with stringent offshore standards.
- Forum Energy Technologies: Forum Energy Technologies completed a demonstration project in Southeast Asia, where its XLX-C ROV executed structural weld repairs on a subsea manifold. The trial validated the ROV’s dexterity in handling complex weld geometries and its integration with advanced vision systems for seam tracking. Forum Energy Technologies emphasized the deployment’s contribution to extending asset lifespans, particularly in aging subsea installations, and paving the way for wider adoption of robotic welding in asset integrity programs.
- Kongsberg Maritime: Kongsberg Maritime collaborated with a European shipyard to deploy its ROVs for underwater hull welding. The project focused on automating routine maintenance welds, cutting dry-docking times by up to 40%. Kongsberg Maritime’s case study highlighted the environmental benefits of minimizing vessel downtime and reducing the risk exposure for human divers.
These deployments underscore a trend toward increasing automation and remote operation in subsea welding, with major manufacturers expected to expand capabilities further through AI integration and modular toolkits over the next few years. The success of these 2025 case studies indicates a positive outlook for the adoption of underwater drone welding technology in critical infrastructure projects worldwide.
Future Outlook: Emerging Trends and Competitive Strategies
The field of underwater drone welding technology is experiencing rapid innovation as operators, equipment manufacturers, and offshore asset owners seek to reduce costs, improve safety, and extend the service life of subsea infrastructure. In 2025, the deployment of remotely operated vehicles (ROVs) and autonomous underwater vehicles (AUVs) equipped with welding capabilities is moving beyond pilot projects into broader commercial application, driven by advances in robotics, power delivery, and sensor integration.
A core trend is the integration of advanced manipulators and power management modules allowing underwater drones to perform complex welding tasks at greater depths. Saab has demonstrated its Sabertooth AUV/ROV platform with modular tooling interfaces, supporting welding and inspection payloads for offshore wind and oil installations. Similarly, Oceaneering International deploys its eNovus ROVs with subsea welding tools, enabling precise in-situ repairs without the need for divers.
Artificial intelligence and machine vision are enhancing the autonomy and reliability of underwater welding operations. Companies like Fugro are incorporating AI-driven navigation and real-time weld quality assessment into their subsea robotics platforms, reducing human intervention and operational downtime. The adoption of digital twin technology, as implemented by TechnipFMC, allows for detailed simulation and remote monitoring of welding processes, increasing project success rates and ensuring compliance with safety and quality standards.
The oil & gas sector remains a primary adopter, but the expansion of offshore wind farms and subsea power cables is creating new market opportunities for underwater drone welding. With aging subsea assets and tightening environmental regulations, asset owners are prioritizing technologies that offer cost-effective, minimally invasive maintenance. According to recent announcements from Subsea 7, the company is investing in ROV-based welding and inspection systems to support the growing demand for offshore renewable energy installations.
Looking ahead to the next few years, competitive strategies will focus on collaborative R&D, standardization of robotic welding interfaces, and development of modular, easily retrofitted tools. Partnerships between subsea drone manufacturers and welding equipment specialists, as seen in the collaboration between Hydratight and major ROV providers, are expected to accelerate the commercialization of fully-automated underwater welding solutions. The market outlook remains robust, with ongoing advancements positioning underwater drone welding technology as a cornerstone of sustainable subsea asset management through 2025 and beyond.
Sources & References
- Saab
- Oceaneering International
- KUKA
- DNV
- Fugro
- Kongsberg Maritime
- TechnipFMC
- DeepOcean
- American Welding Society (AWS)
- International Marine Contractors Association (IMCA)
- American Bureau of Shipping (ABS)
- Saipem
- Ocean Infinity
- Hydratight