Article by METSTRADE
Start-Up Pavilion exhibitor ESEA Propulsion Systems has thrown out the rule book for its new electric outboard design. Metstrade spoke with CEO and co-founder, Carlos Puerta, to learn how his fledgling business has employed emerging technologies to rapidly move from concept to prototype.
Looking at design renderings it doesn’t take long to figure out that Menorca-based start-up ESEA Propulsion Systems has arrived at a very different solution for its fledgling PD100 electric outboard motor design. The powerhead sits much closer to the lower unit than you would expect with a conventional design, providing a reduced profile and minimal intrusion on deck space. The powerhead is fixed with only the leg swivelling 90° either side of centre to provide fascinating potential for high manoeuvrability. The company foresees a motor mount that will enable the PD100 to operate at two heights – displacement and hydrofoil.
Under the hood the company will utilise an axial flux electric motor running at the higher voltages typically supplied by automotive battery packs to provide a 75kW (100hp) continuous power rating output. Target weight excluding batteries is 95kg.
ESEA Propulsion is also planning 35kW (50hp) and 150kW (200hp) models in a similar configuration.
Origins of a new outboard concept
Company CEO Carlos Puerta is an automotive engineer by trade, with 10 years’ experience within the VW-Group. He and ESEA co-founders, Technical Advisor Carlos Garcia and Strategy Advisor Joan Roselló, grew up together since early infancy on Menorca. Culturally they are heavily linked to the sustainability values of that island and that was the motivating force for teaming up to research and develop a new concept of electric outboard motor.
“We have been talking our whole lives about something that we should do regarding the environment,” Puerta explains. “I had seen the transformation between combustion to electric and all the issues around it in the automotive industry. Carlos (Garcia) had been working in nautical sector as a marine engineer and professor, working with internal combustion engine outboards and teaching students at the Polytechnic University of Catalonia. Joan provides the entrepreneurial and business experience. We decided to start with a blank sheet of paper and challenge exactly why an electric outboard should take up so much volume in a boat. We thought very compact electric motors should make it possible to do something completely different.”
A key objective became to create a concept where the powerhead would occupy the space only between two reference lines – the level of the boat deck and its waterline. They did not want to submerge the motor because although there are benefits in reduced vibration and sound emissions, it would lead to high levels of water resistance for the desired performance of their outboard.
Having crafted an early concept and consulted with the Polytechnic University of Catalonia, feedback suggested the team were onto something genuinely new and were advised to start patent processes (now underway in Europe, in the United States, China and Japan). A fourth co-founder has joined the team as CTO – Javier Garrido, a design engineer with 20 years’ experience.
ESEA Propulsion secured funding earlier this year from the Spanish PERTE Naval project which in turn is backed by the NextGenerationEU fund. It was also able to secure bank guarantees thanks friends and family on Menorca. This enabled it to progress from concept towards prototype and work with Spain’s largest applied research and technological development centre – TECNALIA, headquartered in the Basque Country close to the French border.
Prototyping in the virtual world
“TECNALIA is providing technical development support in areas such as finite element method analysis,” Puerta explains. “Despite all the knowledge and experience that we have within our team, we wanted to have the very best expertise to support us and not create a physical minimum viable prototype out of a garage.
“We are resolving many of the technical aspects of the outboard completely virtually. During my 10 years in the automotive industry, I have seen virtual simulations save a lot of money and the product development cycle change from 20 iterative prototypes to five. Computer aided engineering is enabling is to develop the design prior to purchasing parts. We don’t want to spend a lot of money producing a prototype and then realise everything must be redone because it is not working.”
Relying on virtual technologies is also enabling the team to move at pace and demonstrate progress, essential for maintaining the interest of funders and investors. The company plans to start bench testing the outboard at TECNALIA early next year, then move to in-water trials in the spring. To improve the accuracy of its modelling, ESEA will equip its physical prototype with a suite of sensors and then compare the real-world data with its simulations. This will improve accuracy and provide confidence in the results.
By June 2025 it expects to have a minimum viable prototype that is analysed and documented with a strong technical foundation to prove the project is feasible. The current plan suggests deliveries of PD100 production models should occur by May 2026.
Testing disruptive materials and concepts
The start-up’s reliance on emerging technologies is not just in the management of its design either. It plans to test disruptive and innovative materials for construction, such as titanium as a corrosion resistant material for the propeller. It is looking at how to innovate the components of the axial flux motor and its controller to provide best performance from a small volume. Control of the outboard will be fully digitised and able to be controlled from an external device or even a smartphone app.
Shorter term ESEA recognises lithium-based cells are the short-term solution and will use a 60kWh 300V battery for initial tests. But it has its eyes on the future potential of solid-state batteries due to their potential for improved sustainability, low weight and performance.
Finding the right investors and partners
As for now, Puerta is focused on ESEA’s first appearance at METSTRADE, thanks to the Start-Up Pavilion. The company has multiple priorities, not least the important task of attracting more funds: “We are very focused on attracting investors to our project and will be using this opportunity to show that the prototype is already being produced with our virtual testing running well. It will also be good to speak with boatbuilders and potential partners. It is important to extend our market not only in Spain, but across Europe and look for joint ventures in the United States and China – we are very open to find as many connections as we can.”
View the emerging details of ESEA Propulsion Systems’ PD100 outboard here –eseapropulsion.com
