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Additive Manufacturing of Downhole Tools with Desired Degree of Anisotropy at Different Locations in the Same Tool

IP.com Disclosure Number: IPCOM000241230D
Publication Date: 2015-Apr-07
Document File: 1 page(s) / 13K

Publishing Venue

The IP.com Prior Art Database

Abstract

Additive manufacturing (AM) or 3D printing is a process of manufacturing a solid object of a desired shape from a programmed computer model. In AM, an object is built by adding successive layers of materials while layering, depositing, sintering or polymerizing them. Because of this nature of manufacturing, the properties of each layer can be varied by varying the composition of the material, changing the processing temperature, altering the print design to add porosity or to introduce patterns. If the change is made in a gradual way, such as gradually increasing the filler content layer by layer in a polymer, a 3D printed part with high flexibility on one end and high stiffness on the other end could be manufactured. Such a polymer part has the potential to have applications similar to a chevron V-Stack seal, with added potential to improve on pressure rating of such seal system due to the non-discrete design. Similarly, one-component parts with varying degree of thermal properties, electrical properties, hydrophobicity, chemical resistance, etc. at different locations in the same tool can be manufactured. This process can be employed on 3D printing with polymers, ceramics or metals. This invention will help replace multi-component tools with one component tool. Additionally, this is likely to open up new possibilities in tool design, resulting in development of new tools that are not possible to be built with conventional manufacturing.

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Additive Manufacturing of Downhole Tools with Desired Degree of Anisotropy at Different Locations in the Same Tool

Additive manufacturing (AM) or 3D printing is a process of manufacturing a solid object of a desired shape from a programmed computer model.  In AM, an object is built by adding successive layers of materials while layering, depositing, sintering or polymerizing them.  Because of this nature of manufacturing, the properties of each layer can be varied by varying the composition of the material, changing the processing temperature, altering the print design to add porosity or to introduce patterns.  If the change is made in a gradual way, such as gradually increasing the filler content layer by layer in a polymer, a 3D printed part with high flexibility on one end and high stiffness on the other end could be manufactured.  Such a polymer part has the potential to have applications similar to a chevron V-Stack seal, with added potential to improve on pressure rating of such seal system due to the non-discrete design.  Similarly, one-component parts with varying degree of thermal properties, electrical properties, hydrophobicity, chemical resistance, etc.  at different locations in the same tool can be manufactured.  This process can be employed on 3D printing with polymers, ceramics or metals.  This invention will help replace multi-component tools with one component tool.  Additionally, this is likely to open up new possibilities in tool design, resultin...