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A method of manufacturing marine riser buoyancy elements includes providing a master mold and mold inserts such that a range of buoyancy elements may be manufactured from one master mold and providing the mold inserts such that an annular space between the riser main conduit and the buoyancy element

A method of manufacturing marine riser buoyancy elements includes providing a master mold and mold inserts such that a range of buoyancy elements may be manufactured from one master mold and providing the mold inserts such that an annular space between the riser main conduit and the buoyancy elements, or a groove width between the buoyancy elements may be varied during manufacture.

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1. A method of manufacturing a marine riser buoyancy module, the method comprising: manufacturing substantially polygonal marine riser buoyancy elements having an arcuate aspect, the manufacturing comprising: providing a master mold and mold inserts such that a range of buoyancy elements may be manu

1. A method of manufacturing a marine riser buoyancy module, the method comprising: manufacturing substantially polygonal marine riser buoyancy elements having an arcuate aspect, the manufacturing comprising: providing a master mold and mold inserts such that a range of buoyancy elements may be manufactured from one master mold; andproviding the mold inserts such that a helical groove width between the buoyancy elements may be varied during manufacture, andattaching two or more of the buoyancy elements to a riser, next to each other, such that a helical groove is formed by the space between the buoyancy elements, thereby assembling a portion of the buoyancy module. 2. The method of claim 1, further comprising providing the mold inserts such that an annular space between a riser main conduit and the buoyancy elements may be varied during manufacture. 3. The method of claim 1, further comprising casting a desired foam buoyancy module. 4. The method of claim 1, wherein providing a master mold comprises providing a triangular master mold that may be used to mold buoyancy modules with a helical pattern. 5. The method of claim 1, wherein the mold inserts are groove inserts, aperture inserts, or annulus inserts. 6. A method of manufacturing a marine riser buoyancy module, the method comprising: providing marine buoyancy modules comprising axially-split, semi-cylindrical buoyancy elements; andaffixing two or more supplemental buoyancy elements next to each other to an outer surface of the semi-cylindrical buoyancy elements, such that a helical groove is formed by the space between the adjacent supplemental buoyancy elements along a surface of the semi-cylindrical buoyancy elements, thereby assembling a portion of the buoyancy module. 7. The method of claim 6, wherein at least one edge of a supplemental buoyancy element is radiused. 8. The method of claim 6, further comprising filling a gap between edges of the axially-split, semi-cylindrical buoyancy elements with syntactic foam, epoxy resin, or polyurethane resin. 9. The method of claim 6, further comprising coating the helical grooves with a hydrophobic coating. 10. The method of claim 6, further comprising forming fillets at the edges of a groove root using hydrophobic coating. 11. The method of claim 6, wherein the supplemental buoyancy elements are over-molded. 12. The method of claim 6, further comprising drilling a pattern of blind radial holes into an outer diameter of the axially-split, semi-cylindrical buoyancy elements and gluing pultruded fiberglass dowels into the blind radial holes to anchor the supplemental buoyancy elements to the axially-split, semi-cylindrical buoyancy elements. 13. The method of claim 6, wherein the supplemental buoyancy elements are molded with syntactic foam. 14. The method of claim 6, wherein the supplemental buoyancy elements may be affixed to the outer diameter of a buoyancy element with an adhesive and threaded fasteners. 15. The method of claim 6, wherein the supplemental buoyancy elements form two, three, or four grooves equally arrayed around a circumference of the axially-split, semi-cylindrical buoyancy elements. 16. The method of claim 6, wherein a thickness of the supplemental buoyancy element is between 5% and 10% of the outer diameter of the axially-split, semi-cylindrical buoyancy elements.