The oil and gas industry demands components that operate under extreme conditions, where reliability is non-negotiable. For complex parts like downhole tools, conventional manufacturing often introduces long lead times, high costs, and design limitations that create potential points of failure, such as leak paths. Additive Manufacturing presents a clear solution, but only when supported by a robust Design for Additive Manufacturing (DFAM) workflow that can manage the entire process -from design to print -within a single, unified environment.
This presentation provides a practical, in-depth case study of how Baker Hughes is leveraging Oqton's 3DXpert software to industrialize AM for critical, high-value applications. We will detail the transformation of a complex, conventionally machined downhole tool into a production-ready, additively manufactured part.
Troy Falgout of Baker Hughes and Kirill Volchek of Oqton will jointly demonstrate the key software-driven strategies that made this possible:
• Hybrid Modeling for Complex Internals: Utilizing 3DXpert's hybrid (CAD and mesh) kernel to design intricate, "additive-compliant" internal channels, consolidating parts and eliminating potential leak paths. • Integrated Generative
Design: Applying the generative design module for topology optimization to remove excess material based on specific performance and load requirements, reducing both weight and manufacturing time. • The Single-Platform Advantage: Showcasing how a unified workflow - spanning design, topology optimization, support generation, and build preparation -accelerates design iteration, minimizes data translation errors, and drastically cuts the total time from concept to qualified part.
Attendees will leave with actionable insights on how to move beyond prototyping and use an integrated DFAM software strategy to produce more reliable, cost-effective, and high-performance end-use parts for demanding industrial environments.
Learning Objectives:
Understand how DFAM and 3DXpert help eliminate design limitations and leak paths in complex parts like downhole tools, improving performance and reliability.
Understand how hybrid modeling and generative design enable optimized, lightweight components that meet strict industry demands while reducing cost and lead time.
Understand the value of a single-platform workflow to streamline design-to-print, reduce errors, and accelerate industrialization of AM for critical oil & gas applications.
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