3D Printing in the Oil Field Kicks Into Production Mode

Abstract

The biggest oilfield service companies in the world are using 3D printers to make metal components for a growing number of tools and equipment. This is a significant development. It shows how far the needle has moved since these companies first embraced 3D printing more than a decade ago for the rapid prototyping of plastic models. Though the early work is being done on a small scale it gives us the first look at the future of manufacturing in this industry. “Like any technology that evolves quite rapidly, it has tremendous potential,” said Rustom Mody, the vice president of technical excellence at Baker Hughes. “It not only reduces the cost, it accelerates the innovation process, and at the same time it gives you more functionality.” The ability to deliver that trifecta—cheaper, quicker, better—has made the trillion-dollar oil and gas industry the fastest growing user of 3D printing according to some market analysts. In metallic 3D printing, powderized stainless steel and other alloys are melded together with high-precision lasers. Each layer is usually built from the bottom up, hence why many of the technology’s truest advocates prefer the synonymous term additive manufacturing to describe the process of 3D printing. Those working in this field are understandably excited about its capabilities but they are also quick to point out a number of limitations that must be addressed before production-mode 3D printing becomes a more widespread practice. This unfinished business is one reason not a single SPE paper has been written about the topic. As companies climb the steepest part of the learning curve they tend to treat their progress as a trade secret. But the ice is beginning to thaw as more 3D printed components head out into the field. For now those parts are small—less than a cubic foot in volume. They cannot be structural or safety-critical, and companies have had precious little time to evaluate the long-term performance of the materials for things such as corrosion or high temperatures. Additionally, there are no industry-defined standards for printed metal.