AML3D Pioneers World’s Largest 3D Printed Pressure Vessel for ExxonMobil: A Landmark in Metal Additive Manufacturing for Oil & Gas

In a groundbreaking move that signifies a major leap forward for industrial-scale metal additive manufacturing, Australian metal machine manufacturer AML3D has commenced production of what is set to be the world’s largest commercial 3D printed pressure vessel. This monumental project is being undertaken for the U.S. oil and gas giant, ExxonMobil, under a substantial $190,000 contract. The contract encompasses the design and production of an impressive 8-meter long (approximately 26 feet) by 1.5-meter diameter (approximately 5 feet) component. Weighing in at over 2,000 pounds, this substantial pressure vessel will be fabricated in an unprecedented timeframe of just 12 weeks, leveraging AML3D’s proprietary Wire Additive Manufacturing (WAM) technology. This achievement not only underscores the maturity of advanced manufacturing techniques but also firmly positions AML3D at the forefront of innovation in heavy industry.

This pioneering pressure vessel project is an exciting development within the Oil & Gas sector, an industry increasingly turning to additive manufacturing (AM) to address its complex demands for faster, more cost-effective, and robust part production. The ability to rapidly prototype, customize, and produce critical components on demand offers significant advantages over traditional manufacturing methods, which often entail lengthy lead times and substantial tooling costs. The growing reliance on 3D printing technologies within this demanding sector is not merely anecdotal; a comprehensive study conducted by the consulting firm GlobalData projects a remarkable trajectory for additive manufacturing in the oil and gas industry. The study forecasts that the global market for AM in this sector will skyrocket to an estimated $32 billion by 2025 and further expand to exceed $60 billion by 2030. These figures serve as compelling evidence that advanced 3D technologies are poised to play a transformative and indispensable role in shaping the future of the energy industry.

Unlocking Industrial Potential with AML3D’s WAM Technology

At the core of this monumental achievement is AML3D’s innovative 3D printing method, known as WAM, an acronym for Wire Additive Manufacturing. This advanced process is rooted in the Directed Energy Deposition (DED) family of additive manufacturing technologies. Unlike powder-based methods, WAM utilizes metal wires as feedstock, which are precisely deposited layer by layer using an electric arc or laser, similar to robotic welding. This technique allows for the creation of intricate, large-scale metal components with exceptional material integrity.

One of WAM’s most significant advantages lies in its remarkable material versatility. The technology is capable of processing a wide array of high-performance metal alloys, including aluminum, titanium, various steels (such as stainless steel and high-strength low-alloy steels), and nickel alloys. This broad material compatibility is crucial for the oil and gas industry, which requires components engineered to withstand extreme pressures, corrosive environments, and high temperatures. Furthermore, WAM technology operates within an open manufacturing space, meaning it does not require a closed printing chamber, unlike many other metal AM processes. This open-air operation is facilitated by localized inert gas shielding, which protects the molten metal from atmospheric contamination, ensuring optimal material properties and structural integrity. This design offers greater flexibility for printing exceptionally large parts that would be constrained by the build volumes of enclosed systems.

Beyond its impressive fabrication capabilities, WAM technology also offers significant benefits in terms of efficiency and sustainability. The process dramatically reduces manufacturing costs and lead times by enabling the production of near-net-shape parts, thereby minimizing the need for extensive post-machining. This reduction in material waste and energy consumption makes WAM a more environmentally conscious manufacturing solution compared to traditional subtractive methods. Additionally, WAM boasts the unique ability to repair damaged or worn-out parts directly, extending the lifespan of critical components and further enhancing operational efficiency. This capability is particularly valuable in industrial settings where equipment downtime can lead to substantial financial losses. The proven track record of WAM technology, including AML3D’s successful production of the largest verified oil & gas piping component last year, undoubtedly played a pivotal role in ExxonMobil’s decision to entrust this critical project to AML3D.

Details of the Record-Breaking Pressure Vessel and Strategic Impact

The pressure vessel currently being manufactured by AML3D is a marvel of engineering, boasting a formidable weight of approximately 2072 lbs (940 kg), an impressive length of 8 meters, and a diameter of 1.5 meters. This colossal component is destined for critical refinery operations within the United States, where it will play a vital role in processing and storage. Before its deployment, the vessel will undergo rigorous strength and hydrostatic pressure testing, adhering to stringent industry standards to ensure its integrity and certify its suitability for demanding applications in the oil and gas environment. Such extensive testing is paramount for pressure vessels, which operate under extreme conditions and whose failure could have severe consequences.

Commenting on this significant achievement, AML3D’s Managing Director, Andrew Sales, highlighted the strategic importance of the contract. He stated, “Signing this deal with ExxonMobil is a further demonstration of delivery against our multi-phase growth strategy. We have a major focus on building our capability and presence in the global Oil and Gas sector as an immediate value driver for the business and this contract absolutely aligns with that objective.” This statement underscores AML3D’s clear strategic direction to penetrate and expand its influence within the high-value oil and gas market, leveraging its unique technological advantages. The manufacturing process itself will be a testament to AML3D’s operational capacity, with five of the eight ARCEMY printers installed at their facility in Adelaide, Australia, dedicated to this project. These advanced robotic metal 3D printing systems will operate at an impressive 75% capacity utilization during the production period, showcasing AML3D’s ability to handle large-scale, concurrent manufacturing demands efficiently.

Revolutionizing Lead Times and Promoting Sustainable Manufacturing

Perhaps one of the most compelling aspects of this project is the dramatic reduction in manufacturing lead time promised by AML3D’s WAM technology. The company asserts that it will deliver the completed pressure vessel in a remarkable 12 weeks. This stands in stark contrast to traditional manufacturing methods, which, due to complex fabrication processes, material sourcing, and global supply chain constraints, would typically require an estimated 12 months or even longer for a component of this size and complexity. This ten-fold acceleration in production speed is a game-changer for industries where time-to-market and operational uptime are critical factors.

Andrew Sales further elaborated on the disruptive potential of their technology, stating, “Our proven WAM^® technology disrupts traditional industrial-scale metal manufacturing by producing superior components with a significantly shorter production cycle and a far more sustainable methodology involving less waste and lower energy input. Our understanding is, due to supply chain constraints, some traditional manufacturers were estimating a delivery date in excess of 12 months. AML3D will deliver a superior component in less than half that time.” This emphasizes not only the speed advantage but also the significant environmental benefits. WAM’s ability to create near-net-shape components reduces the amount of raw material required and subsequently minimizes machining waste. Furthermore, the localized and automated nature of the process often translates to lower energy consumption compared to conventional forging, casting, or machining processes that involve multiple complex steps and transportation. In an era where industries are increasingly focused on sustainability and reducing their carbon footprint, AML3D’s WAM technology offers a compelling solution that aligns with global environmental objectives.

The partnership between AML3D and ExxonMobil for the production of the world’s largest 3D printed pressure vessel is more than just a contract; it’s a testament to the transformative power of metal additive manufacturing. It highlights the growing confidence of major industrial players in these cutting-edge technologies and sets a new benchmark for what is achievable in large-scale, high-performance component fabrication. As the oil and gas sector continues its drive towards efficiency, cost reduction, and sustainability, innovations like AML3D’s WAM are proving to be indispensable tools for navigating future challenges and unlocking new opportunities.

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*Cover Photo Credits: AML3D