With the Energy sector spanning both hydrocarbon and renewable energy sources, part production is a critical part of the supply chain to ensure the efficient operation of any energy asset in the Oil and gas, Renewable, or Nuclear sectors.
Embracing digital connectivity can provide measurable benefits, especially when producing safer, reliable, and more efficient parts. From components for wind turbines and solar panels to valves and pipes for the oil and gas industry, digital manufacturing can help get parts to production quickly and efficiently in an industry with constantly evolving supply targets and demanding application requirements.
Working with these sectors, we have gathered 7 of the most important and frequently asked questions.
1. How can your manufacturing solutions improve the durability and performance of our equipment in extreme environments?
Manufacturers like Protolabs can guide part design to ensure the creation of strong, durable shapes and identify the most effective techniques and tools for final production. Prototyping can help resolve any issues early in the process and enhance equipment performance. Material selection can affect durability, as certain materials are more commonly used in specific sectors based on their characteristics; engineers can recommend how to improve durability.
2. What custom manufacturing capabilities can manufacturers offer for oilfield and offshore equipment?
Many oilfield services companies are branching out into other sectors and extending their capabilities to carve out a new future. Innovation, development, and striving towards net-zero carbon emissions mean big transition opportunities, and custom manufacturing capabilities such as CAD design support, CNC Machining, 3D Printing, and Injection moulding can help facilitate these changes. Protolabs offers 80+ materials, and design experts can help pick suitable materials based on desirable features.
3. How do you ensure the reliability and quality of components used in high-pressure and high-temperature conditions?
Within the energy industry, there is a requirement for highly engineered solutions. Chemical, corrosion and temperature resistance, durability, and the ability to function in extreme environments are essential. Injection moulding offers benefits such as bridge-tooling and on-demand parts, which are ideal for parts that need to be produced repeatedly. Experts can make recommendations on design and material to ensure the reliability and quality of components used in high-pressure and high-temperature conditions. For example, 3D printed Inconel 718 can be used at temperatures between -252°C and 704°C due to its ability to create a think, stable passivating oxide layer at high temperatures.
4. How do you ensure compliance with industry standards and regulations in your manufacturing processes?
Protolabs recently achieved ‘Qualification of Manufacturer’ certification from independent risk management and assurance expert DNV for its direct metal laser sintering (DMLS) technology, specifically for use with the superalloy Inconel 718 for harsh offshore and onshore environments. The award means the company is the first certified manufacturer in the world using powder bed fusion technology.
5. What support do you provide for product design and customisation to meet specific operational needs?
Customisation and design adaptation are possible before and after prototyping. Protolabs offers a quick and efficient Design for Manufacturability (DFM) service, providing quotes within hours. An expert team of Application Engineers can also help finalise manufacturable parts.
6. Can you provide cost-effective solutions for large-scale infrastructure projects in the energy sector?
Economies of scale are crucial for large-scale projects, and custom manufacturing offers a flexible, scalable approach. Protolabs, for example, can support these projects with a wide selection of materials, including high-performance alloys like Inconel 718, which are ideal for extreme environments. Moreover, integrating digital manufacturing technologies facilitates quicker design iterations, reducing lead times and minimising project delays.
7. Can you provide solutions for reducing downtime and maintenance costs in our energy operations?
The manufacturing industry relies on fast, responsive processes to minimise non-value-added time and effectively manage downstream disruptions. Implementing safeguards ensures thorough product evaluations, early problem detection, and resource conservation during supply chain disruptions. Companies in the energy, oil, and gas sectors face unique challenges that demand innovative, efficient manufacturing solutions.
By adopting digital connectivity and advanced manufacturing technologies, businesses can enhance the durability, performance, and sustainability of their equipment. The ability to produce parts quickly and reliably reduces downtime ensures regulatory compliance and meets the evolving demands of the energy sector. 3D printing has the potential to play a pivotal role in sustaining the global oil and gas industry by increasing financial efficiency, delivering unparalleled precision engineering, supporting safety initiatives, and reducing the sector's carbon footprint. It may be time for the industry to embrace a new, more effective way forward.
