US shipbuilder Senesco Marine has contracted ABB to deliver full propulsion and automation systems for a 75-car electric passenger and vehicle ferry, which will replace the 45-year-old ‘Cape Henlopen’ in connecting Lewes, Delaware and Cape May, New Jersey.
A trend has been observed by ABB in North America for modernisation of the busiest ferry routes, employing efficient electrification central in updated fleets. An integrated hybrid-electric propulsion system from ABB has been selected for the new ship ordered by Delaware River and Bay Authority (DRBA). Construction will start at the Rhode Island-based yard in mid-2026.
ABB’s scope of supply includes a high redundancy propulsion system comprising flexible Onboard DC Grid power platform, and PEMS power and energy management system, as well as engineering, acceptance testing, training and commissioning support.
Established in 1964, the Cape May–Lewes Ferry route has served more than 50m passengers and supports over 4,000 regional jobs. The 17-mile Cape May-Lewes transit offers an alternative to spending hours on the highway between New Jersey and Delaware.
Expected to improve efficiency, reliability, and customer experience, the new ferry is due delivery in 2029 as part of DRBA’s fleet modernisation initiative. Unlocking initial fuel savings of around 35%, as well as lower operating and maintenance costs compared to the existing fleet, the ship will enter service as a diesel-electric vessel, but with the capability to install a 7,000kWh battery pack for an all-electric upgrade. Developed by Elliott Bay Design Group and classed by ABS to meet US Coast Guard requirements, its arrival will signal a major step forward in DRBA’s strategy to cut regional emissions of NOx, particulates, hydrocarbons, carbon monoxide and CO2. The delivery is one of 18 projects under the 2024 US$ 300m Department of Transportation nation-wide funding program supporting hybrid and electric ferry upgrades to advance cleaner, lower emission ferry systems.
Ted Williams, President, Senesco Marine, said: “Senesco Marine is truly excited to have been awarded the DRBA contract for the Cape May Lewes Ferry. We are absolutely thrilled to be working alongside ABB on this project, especially given their remarkable expertise and proven success in the hybrid propulsion space.”
Timo Vesala, Head of Sales, Marine Systems, Americas, ABB Marine & Ports division, added: “ABB is proud to support the modernisation of the Cape May–Lewes Ferry with hybrid-electric propulsion technology developed and supported here in the United States. This project builds on our long-standing commitment to helping American shipyards and coastal communities move toward cleaner, more efficient marine transportation. Our solutions are entirely scalable, and our ferry projects range from the biggest electrification programmes to smaller vessels with very tailored needs. We look forward to working with Senesco Marine and the Delaware River & Bay Authority to deliver the next generation of sustainable ferry operations.”
In December 2025, ABB announced an order from Washington State Ferries (WSF) to support the US’s largest ferry operator’s System Electrification Program by supplying and integrating hybrid-electric propulsion systems for two hybrid-electric 160-vehicle ferries.
Image: Cape May-Lewes new 75-car hybrid-electric ferry (credit: Elliott Bay Design Group)
