Additive Manufacturing for Energy (Oil and Gas)

Additive manufacturing in the energy sector, particularly in oil and gas, allows for the creation of robust, specialised components that endure harsh environments, such as drilling equipment, pipelines, and heat exchangers. With AM, the energy industry can overcome logistical challenges and reduce dependency on extensive inventories.

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Benefits

Complex Component Production: Manufacture intricate parts, including those for high-pressure, high-temperature applications, without compromising on strength. ...
Speedy Prototyping and Production: Expedite design iterations and production of operational parts, reducing downtime for critical equipment. ...
Resilient and Lightweight Parts: Build parts that are both durable and lighter, reducing transportation and installation costs. ...
On-Demand Manufacturing: Produce parts when and where they’re needed, overcoming remote location challenges in the oil and gas sector. ...
Material Efficiency: Lower costs and reduce waste in a traditionally resource-heavy industry. ...
Environmental Considerations: Decrease emissions by reducing transport and raw material requirements, supporting sustainability goals in energy production. ...

What We Offer

Custom component fabrication

Rapid prototyping and iteration

On-site / remote deployment

Durability under harsh conditions

Light-weighting

Materials

To meet the rigorous demands of oil & gas applications, we use materials chosen for their thermal stability, mechanical strength, chemical resistance, and suitability for AM.
Some examples:

Material	Key Properties	Typical Use Cases
PEEK / PEKK (High-performance polymers)	Very high temperature resistance (often up to ~250-300 °C or more), excellent chemical resistance, strong mechanical properties	Seals, gaskets, insulating parts, components in contact with corrosive fluids, insulating layers in heat exchangers
Ultem (Polyetherimide)	High thermal, flame and chemical resistance, UV stability	Components near heat sources, interior parts in refinery, parts for electrical enclosures
Nylon (Carbon-filled, Glass-filled)	Good toughness, moderate temperature resistance, good abrasion/corrosion resistance after post-processing	Wear-prone components, bushings, fittings, housings, custom brackets
Stainless Steel (316L, 17-4PH etc.)	Excellent corrosion resistance, strength at elevated temperature, good weldability / finishing	Flanges, connectors, structural components, piping splice parts
Titanium / Inconel / Exotic Alloys	For very high temperature, high strength, extreme corrosion, and offshore/deep-sea environments	Valve components, high-pressure fittings, parts submerged or in subsea environments
Composite / Fibre-reinforced polymers (e.g. carbon fibre reinforced)	High strength-to-weight ratio, good fatigue resistance	Lightweight covers, non-structural panels, auxiliary components where weight is a concern

Applications

High-Pressure Valve Seat

Drill Bit Retainer Clip

PEKK Seal for Pipeline Repair Clamp

Real World 3D Printing Success Story

A 3D-printed repair clamp reduces pipeline downtime

HSB is the largest service provider for public transportation in eastern Germany. They use the state-of-the-art 3D scanning technology of the ZEISS T-SCAN hawk 2 to ensure that their steam locomotives run non-stop and that their traditional drives are preserved for the future. Accurate 3D models of the machines support the maintenance, repair and overhaul – keeping a part of German history alive in the Harz mountains.

View case study

Oil & Gas seals fabrication via FFF: the gap with conventional manufacturing methods

These technical results firmly established PEKK additive manufacturing as an alternative for producing high performance parts via a near-net shape approach. As designers and engineers more widely embrace additive manufacturing, there must be a stronger focus on the economic justification of this new process.