Green Star Marine

Marine product development

Website

About the firm

Green Star Marine delivers marine-focused engineering and expertise, supporting clients from consulting and design through prototype building, testing, and full product development.

Established
2011
Team
Micro
Firm type
Marine Engineering · Mechanical Engineering · Electrical Engineering · Naval Architecture

People

Tom WalczakFounder & CEO

Alec WalczakHead of Projects

Capabilities

Marine Product Development

Service website

Offers comprehensive product-development support for marine systems, guiding projects from initial requirements and engineering design through to prototype construction, validation, and market launch.

  • Prototype Build & Testing

    Constructing physical product prototypes and conducting rigorous testing to validate designs.

  • Industrial Design

    Creating artistic renderings of ideas and structural concepts.

  • Supply Chain & Sourcing

    Providing access to marine product sources with deep knowledge of aquatic environments and material performance.

Marine Mechanical Engineering

Service website

Delivers mechanical engineering services encompassing the design, integration, assembly, and testing of complex vessel propulsion and mechanical systems.

  • Propulsion Integration

    Designing and integrating inboard and outboard engines for marine vessels.

  • Noise, Vibration, and Harshness (NVH)

    Implementing design strategies to minimize noise, vibration, and harshness.

  • Gears & Drivetrain

    Engineering gears, gearboxes, transmissions, and driveline components.

Design & Analysis

Service website

Uses advanced engineering tools and simulations to optimize structural, hydrodynamic, and thermal performance.

  • Computational Fluid Dynamics (CFD)

    Designing and optimizing vessel hulls and hydrodynamic bodies.

  • Finite Element Analysis (FEA)

    Conducting detailed structural analyses of system shapes and material properties.

  • Naval Architecture

    Designing and validating vessel hulls and running surfaces.

Electrical & Software Systems

Service website

Designs electrical architectures and writes custom software to power marine vessel control systems and electronics.

  • Electrical Architecture & Wire Harnesses

    Designing and manufacturing robust electrical wire harnesses for marine environments.

  • PCB Design & Manufacturing

    Designing and manufacturing printed circuit boards tailored to aquatic environments.

  • Software & Firmware Development

    Developing firmware, software applications, vessel controllers, and AI integrations.

Industries

Marine · Manufacturing · Defense

Projects

Caudwell Marine AX300 Development

Marine · Client: Caudwell Marine

Project details

Provided engine integration, cowling design, and air intake engineering expertise, alongside developing a DVP&R for validating an outboard engine.

Photon Marine P300 Electric Outboard

Marine · Client: Photon Marine

Project details

Designed a full-stack electric outboard engine, including the mechanical housing, midsection, lower unit, cooling system, and electrical motor integration.

Seakeeper SK1 Enclosure Development

Marine · Client: Seakeeper

Project details

Developed a unique weatherproof enclosure for the Seakeeper 1 stabilizer to support deck-mount installations on small boats.

Evoy Breeze Inboard Engine Integration

Marine · Client: Evoy

Project details

Partnered to design and bring a fully electric Breeze inboard engine to market, successfully overcoming resource constraints for product launch.

Green Star Marine - Engineering Firms