Manager's Guide to Additive Manufacturing in the Oil and Gas Sector
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Chapter One: Introduction to Additive Manufacturing for the Oil and Gas IndustryÂ
1.1 How Oil and Gas Industry Dynamics Affect Adoption of AMÂ
1.1.1 Why Oil and Gas Supply Chain Companies Attract AMÂ
1.1.2 The Need to Ensure the Reliability of 3D Printed Oil and Gas Parts and ProcessesÂ
1.2 Why Invest in Additive Manufacturing?Â
1.2.1 Oil and Gas Companies are Ready to Spend on Additive ManufacturingÂ
1.2.2Â Keeping the Supply Chain Optimized with New TechnologiesÂ
1.2.3 Pressure on the Supply ChainÂ
1.3 Who Will Adopt Additive Manufacturing in the Oil and Gas Industry?Â
1.4 How Far Along are You in the AM Adoption Model for Oil and Gas?Â
1.5Â Why Should You Introduce AM in Your Supply Chain?Â
 Chapter Two: Learning to 3D Print in Oil and Gas: the Additive Manufacturing SystemsÂ
2.1 Overview of AM Hardware Adoption by the Oil and Gas IndustryÂ
2.1.1 AM Technologies for the Oil and Gas Industry Considered in This ReportÂ
2.1.1.1 Looking Further Down the Line at Future TechnologiesÂ
2.1.2 Why Should You Invest in an Additive Manufacturing System?Â
2.1.2.1 Do Away with Expensive ToolsÂ
2.1.2.2 Enjoy Complete Freedom of GeometryÂ
2.1.2.3 Do Away with Time Consuming Sub-assemblies (and Related Costs)Â
2.1.2.4 Do Away with Physical Inventory (and Related Costs)Â
2.2 Getting Familiar with the Primary Metal AM Technologies that can be Used for Oil and Gas ApplicationsÂ
2.2.1 The Three Primary Metal AM Technologies that you Need to KnowÂ
2.2.1.1 Powder Bed FusionÂ
2.2.1.2 Directed Energy DepositionÂ
2.2.1.3 Metal Binder Jetting / Bound MetalÂ
2.2.2 Transitional AM TechnologiesÂ
2.2.2.1 Bound Metal Filament Deposition Desktop SystemsÂ
2.2.2.2 Sand-based Binder Jetting for CastingÂ
2.3 Polymer AM for Oil and Gas Applications of which You Need to be AwareÂ
2.3.1 Latest Evolutionary Trends in Polymer AM HardwareÂ
2.3.1.1 Polymer Powder Bed Fusion Will Be Used for Final Part ProductionÂ
2.3.1.2 Photopolymerization Can Serve Several Different PurposesÂ
2.3.1.3 Material Extrusion: the Differences Between Pellets and FilamentsÂ
 Chapter Three: Learning to 3D Print (Part 2): Which Materials Can You Use?Â
3.1 Latest Materials DevelopmentsÂ
3.2 Which Metals Can You Use to 3D Print Oil and Gas Parts?Â
3.2.1 3D Printing with Steel and Steel AlloysÂ
3.2.1.1 Steels Binder Jetting for Mass ProductionÂ
3.2.2 3D Printing with Nickel AlloysÂ
3.2.3 3D Printing with Cobalt ChromiumÂ
3.2.4 3D Printing with TitaniumÂ
3.2.4.1 Titanium Wire for WAAMÂ
3.2.5 3D Printing with Other Metals (Refractories, Tungsten Carbide, Tantalum, Molybdenum, Niobium)Â
3.3 Polymer and Composite Materials for Oil and Gas AMÂ
3.3.1 Where to Get the Best Polymer 3D Printing Materials for Use in Oil and GasÂ
3.3.2 Using Polymers and Composites to Replace MetalsÂ
3.3.3 Did You Know You Can Now 3D Print Parts of Any Size Using Composite Pellets?Â
3.3.4 The Multiple Uses of Digital MaterialsÂ
3.3.5 Discovering the Future Opportunities of Advanced Materials for Polymer Powder Bed FusionÂ
3.4 3D Printable Ceramics You Need to Be Aware of for Future ApplicationsÂ
3.4.1 Ceramics AM Technologies for Oil and GasÂ
3.4.2 Direct Production and 3D-printed CastsÂ
3.4.3 Advanced Ceramics for Oil and Gas ApplicationsÂ
 Chapter Four: What You Can Actually Do with Additive Manufacturing in Oil and GasÂ
4.1 Practical Applications of Additive Manufacturing in Oil and GasÂ
4.1.1 Which Oil and Gas Parts Can Be 3D Printed?Â
4.1.1.1 Prototypes and ModelsÂ
4.1.1.2 Molds, Cast Patterns, Jigs and FixturesÂ
4.1.1.3 Drill Bits and Drill ComponentsÂ
4.1.1.4 Sensors and Associated HousingsÂ
4.1.1.5 Combustion Systems and TurbomachineryÂ
4.1.1.6Â Fittings and Pump ComponentsÂ
4.1.1.7 Heat ExchangersÂ
4.1.1.8 Components for Gas Processing and Refinery OperationsÂ
4.1.1.9 Catalytic Reactors and ComponentsÂ
4.1.1.10 Hydraulic ManifoldsÂ
4.1.1.11 Crane Hooks, Propellers and Other Large Maritime PartsÂ
4.2 Overview of the AM Product and Process LifecycleÂ
4.3 Learning to Design Oil and Gas Parts for Additive ManufacturingÂ
4.3.1 Basics of DfAM (Design for Additive Manufacturing)Â
4.3.2 Generating Parts with SoftwareÂ
4.4 The Future of Oil and Gas Will Be Additively ManufacturedÂ
4.4.1 How to Get Clear Process and Material Guidelines for Additively Manufactured Oil and Gas PartsÂ
4.4.2 Sample Application Cases for Prototypes and ModelsÂ
4.4.3 Sample Application Cases for Part Replacement and Final PartsÂ
4.4.3.1 Accelerating AdoptionÂ
4.4.3.2 Short-term Benefits of On-Demand Part ReplacementÂ
Chapter Five: Your Key Oil and Gas Suppliers of Additive Manufacturing Services and GuidelinesÂ
5.1 Recent Activity in AM by OEC FirmsÂ
5.1.1 Saudi AramcoÂ
5.1.2 Sinopec GroupÂ
5.1.3 China National Petroleum CorporationÂ
5.1.4 Royal Dutch ShellÂ
5.1.5 BPÂ
5.1.6 TotalÂ
5.2 Recent Activity in AM by Key Oil and Gas Industry Suppliers and StakeholdersÂ
5.2.1 General ElectricÂ
5.2.2 SiemensÂ
5.2.3 DNV GLÂ
5.2.4 Lloyd’s RegisterÂ
5.2.5 Recent AM Activities by Other Relevant Oil and Gas Suppliers and StakeholdersÂ
5.2.5.1 voestalpine Oil and GasÂ
5.2.5.2 RepsolÂ
5.2.5.3 WoodsideÂ
5.2.5.4 Wilhelmsen and Ivaldi GroupÂ
5.2.5.5 KennametalÂ
5.2.5.6 AidroÂ
5.2.5.7 WartsilaÂ
5.2.5.8 EquinorÂ
5.2.5.9 TrelleborgÂ
About SmarTech AnalysisÂ
About the AnalystÂ
Acronyms and Abbreviations Used In this ReportÂ
List of ExhibitsÂ
Exhibit 1-1: Oil and Gas Supply Chain Dynamics for AM Parts ProductionÂ
Exhibit 1-2: Aspects of the process chain and their influence on parameters of additive manufacturing process.Â
Exhibit 1-3: SmarTech Analysis’s Additive Manufacturing Adoption Model for Oil and Gas MarketsÂ
Exhibit 1-4: Efficiency Improvements Possible by Adopting AM into Supply ChainÂ
Exhibit 1-5: Using AM to Address Biggest Challenges for Oil and GasÂ
Exhibit 2-1: AM Hardware Technologies Used in Oil and Gas and Their Primary Applications (for larger size chart see the next page)Â
Exhibit 2-2: Leading Metal AM Hardware Technologies and Manufacturers Used in Oil and GasÂ
Exhibit 2-3: Primary Polymer AM Processes and System ManufacturersÂ
Exhibit 3-1: Relevance of Metals in Oil and Gas AMÂ
Exhibit 3-2: Key Identified Metal AM Material Development Initiatives by Print TechnologyÂ
Exhibit 3-3: Summary of Most Common Types of Steel Additive Manufacturing Powders and ProcessesÂ
Exhibit 3-4: Large Format Additive Manufacturing Systems (LFAM)Â
Exhibit 4-1: Typical and Potential Additively Manufactured Parts by Oil and Gas Industry SegmentÂ
Exhibit 4-2: Typical Lifecycle for Materials/Products Produced Through Additive ManufacturingÂ
Exhibit 4-3: Traditional Prototyping vs. Rapid Prototyping with 3D PrintingÂ
Exhibit 5-1:Â Map of Companies that Have Made Public Announcements About AM Integration into their Supply Chain Between 2016 and 2018Â
After a few years of evaluating and studying additive manufacturing applications, the oil and gas industry is now readying for full industrialization and implementation. After a challenging period due to dropping prices, the oil and gas sector is now ready to invest again. Additive manufacturing can provide some of the best value propositions for part production in the upstream, midstream and downstream segments, as well as energy generation.
Learning from experiences in rapid prototyping and tooling within other industries, such as the aerospace, automotive and medical sectors, many oil and gas operators and suppliers are now looking to use additive manufacturing in order to gain a key competitive edge in the production of advanced and complex final parts. The key next phase is going to be the development of clear guidelines and standards – and identify the ideal technologies and materials – for the full industrialization of additive manufacturing into the oil and gas manufacturing workflow.
Due to its great engineering challenges, its massive global scale and part size requirements, the oil and gas industry is slated to become the next great additive manufacturing adoption segment over the next decade. SmarTech has identified oil and gas industry part an services suppliers as the primary customers investigating this market and developed this Manager’s Guide to help facilitate the journey.
This Manager’s Guide Will Include:
- The guidelines for process an part requirements for additively manufactured oil and gas parts
- An overview of the hardware technologies that are ideally suited for oil and gas part production.
- An in-depth discussion on the various applications within the different segments of the oil and gas supply chain: upstream, midstream and downstream.
- A critical analysis of the advantages from implementing additive manufacturing in rapid and multiple iteration prototyping, tooling (including jigs and fixtures) and direct part production
- A detailed analysis of the types of parts that can be produced with additive manufacturing in oil and gas.
- A discussion of the key materials (including primarily metals but also polymers, ceramics and composites) that can be used in additive manufacturing of parts for oil and gas applications.
This report is directed toward the end user market, the companies who are active users of additive manufacturing or considering its adoption. While suppliers of additive manufacturing may find the report useful this study differs from our related study,  The Market for Additive Manufacturing in the Oil and Gas Sector 2018-2029 which provides broader analysis and forecasting of the addressable market for the supply chain.