Additive Manufacturing in the Oil Gas Industry: Strategies for Managing Powder Waste in Multi Jet Fusion Printing (MJF)

Abstract

In the context of the Product Development Process (PDP), particularly during the development phase, there is growing recognition of the importance of waste management in producing components used in the industry. This increased awareness has led to a progressive interest in formulating approaches to understand and mitigate the possible resulting environmental impacts. Within this context, considering the substantial increase in the application of Additive Manufacturing techniques in the oil and gas industry, especially the deposition of polymeric layers, notably through the use of PA 12 and PP powder, it becomes imperative to thoroughly examine the production process in order to assess the feasibility of reincorporating discarded materials into the production chain of polymeric materials. In this context, this article proposes a detailed analysis of the manufacturing flow of a Multi Jet Fusion (MJF) Additive Manufacturing machine to assess the percentage of waste generated in small-scale prints by quantifying the mass of waste generated in the process, as well as pointing out alternatives for disposing of this waste. When the parts are produced, PA12 and PP powder waste is generated; in this deposition process, the powder is reused, returning to its production process. However, after the part has been made, it needs to be blasted with glass microspheres to remove all the powder residue that is trapped in the part. The waste generated during blasting is a mixture of PA12, PP, and glass microspheres, which, if not disposed of in an environmentally appropriate way, can have an environmental impact. Over 9 days, the results revealed an average of 12.15% waste from the component blasting process. It is suggested that this waste be used to manufacture filaments by extrusion and in additive manufacturing machines to deposit molten material. This material can produce other components for the oil and gas industry using FDM printers. It should be noted that bibliographical references identify viable techniques for reintegrating discarded materials into other manufacturing processes. Reducing PA12 and PP waste in additive manufacturing contributes to economic efficiency. It aligns with environmental and social goals, promoting sustainable practices and supporting the achievement of the Sustainable Development Goals in the oil and gas sector.