The National Institute of Ocean Technology (NIOT), under the Ministry of Earth Sciences (MoES), Government of India, is at the forefront of developing indigenous technologies to address engineering challenges associated with the sustainable utilization of oceanic resources. Deep-sea components are exposed to harsh environmental conditions, including extreme hydrostatic pressures, low temperatures, biological fouling, high salinity and steep gradients of these factors between the surface and seabed. Additive manufacturing (AM) has emerged as a transformative solution to these challenges, offering the ability to produce complex geometries, customized designs and material-efficient components. AM now encompasses a variety of materials, including polymers, metals, ceramics and composites, enabling innovative manufacturing approaches. At NIOT, High Impact Polystyrene (HIPS) and Acrylonitrile Butadiene Styrene (ABS) were selected as suitable materials for fabricating subsurface floats and protecting cover for glass floats used in buoy systems. These components were manufactured using the Fused Deposition Modeling (FDM) technique with a pellet-based extrusion system. Subsurface floats are designed for water depths of 500 m (50 bar working pressure), while protective cover operate at depths up to 3000 m (300 bar working pressure), the components underwent rigorous testing. This study highlights NIOT’s pioneering efforts to revolutionize deep-sea component design through additive manufacturing while exploring its future potential. The findings emphasize AM's ability to enhance work safety, minimize environmental impact and improve efficiency in deep sea applications. Further advancements in AM technology and material optimization, coupled with the integration of artificial intelligence, are expected to drive innovations in design, quality control and production, transforming the field of deep-sea engineering.