Skrevet af
Peter HansenPeter Hansen er medstifter og 3D-print-ekspert hos 3D Industri Print. Han har over 10 års erfaring med industriel 3D-printproduktion, herunder FDM, SLS og DMLS-teknologier. Peter rådgiver virksomheder om materialevalg, tolerancer og optimering af produktionsflow med additivt fremstilling.
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Additive Manufacturing in the Oil and Gas Industry
The oil and gas industry presents some of the most demanding material requirements of any sector: extreme pressures, corrosive media, high temperatures, and uncompromising reliability requirements. Metal 3D printing — specifically DMLS using Inconel and corrosion-resistant alloys — is increasingly the solution for components where conventional manufacturing falls short or where lead times for critical spare parts are unacceptable.
Core Problems 3D Printing Solves in Oil & Gas
Legacy Equipment Spare Parts
Offshore installations operate for 20–40 years. Original equipment manufacturers (OEMs) stop producing spare parts for pumps, compressors, and valves long before the platform reaches end of life. With 3D scanning and metal 3D printing, these components can be reproduced precisely — even without original CAD documentation.
The alternative — taking the platform offline while waiting for OEM fabrication — costs millions in lost production per day.
Complex Internal Geometries
Valve bodies, flow conditioners, and compressor components with internal channels and complex geometries are expensive and time-consuming to machine. Metal 3D printing builds these geometries directly from CAD, including conformal internal channels and features impossible to reach with cutting tools.
Rapid Response to Unplanned Downtime
When a critical component fails offshore, every day of downtime has a quantifiable cost. Metal 3D printing can deliver replacement parts in days or weeks rather than the months required for conventional forging and machining.
Materials for Oil & Gas 3D Printing
| Material | Grade | Properties | Applications |
|---|---|---|---|
| Inconel | IN625 | Corrosion resistant, strong at 980°C, acid resistant | Subsea components, sour wells, process piping |
| Inconel | IN718 | High tensile strength at elevated temperature | Turbine components, compressor wheels |
| Stainless Steel | 316L | Marine corrosion resistance | Fittings, flanges, process equipment |
| Duplex Steel | 2205 | Double the strength of 316L, HISC resistant | Subsea pipelines, pump components |
| Titanium | Ti-6Al-4V | Lighter than steel, resistant to seawater corrosion | Lightweight structures, subsea applications |
Certification and Standards
Oil and gas components demand rigorous documentation. For 3D printed components, the applicable standards typically include:
- NORSOK M-650 — Norwegian offshore standard for materials and manufacturing qualification
- DNV GL certification — type approval and component certification
- ASME B31.3 — process piping systems
- API 6A / 17D — wellhead and subsea components
- EN 10204 3.2 — material certification with third-party inspection
We provide EN 10204 3.1 material certificates as standard and coordinate third-party certification (DNV, Bureau Veritas, Lloyd’s Register) on request.
Post-Processing for Oil & Gas Applications
- Heat treatment — stress relief and microstructure homogenisation
- HIP (Hot Isostatic Pressing) — eliminates internal porosity; mandatory for pressure-retaining components
- CNC machining of critical surfaces — sealing faces and mating surfaces to specified tolerances
- NDT — CT scanning, ultrasonic inspection, magnetic particle inspection
- Pressure testing — hydrostatic test to specified proof pressure
North Sea Case Study
An operator with a failed valve on a North Sea platform contacted us. OEM lead time: 16 weeks. Platform production loss: ongoing.
We reverse-engineered the component from a 3D scan, printed in Inconel 625, heat-treated, and CNC-finished the critical sealing surfaces. Total time from scan to approved component: 6 weeks. The platform returned to production 10 weeks ahead of the OEM’s delivery.
Working with Danish and Norwegian Offshore Operators
We partner with operators, EPC contractors, and suppliers on certified metal 3D printed components for offshore and onshore oil and gas applications. Our services are particularly relevant for the Danish North Sea sector and the Norwegian Continental Shelf supply chain.
