System and method for 3-d printing of rubber in downhole devices

Abstract

A method for three-dimensional (3D) printing rubber in a downhole device (510), such as a mud motor or a downhole pump. The method includes positioning a print head (506) mounted on a heated feed line (504) within the downhole device; coupling the print head to an emitter (508) mounted on the heated feedline; connecting the print head to an external extruder for feeding rubber; injecting the rubber through the print head at a first location of the housing of the downhole device and vulcanizing the rubber during printing; solidifying the rubber before the print head is moved out of contact with the solidified portions of the rubber; and moving the print head to a second location of the housing of the downhole device.

Description

Attorney Docket No.: 65DHM-510991-WO-2 (000248)SYSTEM AND METHOD FOR 3-D PRINTING OF RUBBER IN DOWNHOLE DEVICES CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of co-pending U. S. Provisional Application Serial No. 63 / 733,241, filed December 12, 2024, the entirety of which is incorporated by reference herein in its entirety and for all purposes.BACKGROUND OF THE INVENTION1. Field of Invention

[0002] The present disclosure relates to three-dimensional (3-D) printing, and more specifically is directed to 3-D printing of Fused Filament Fabrication (FFF) rubber material in a downhole motor.2. Description of Prior Art

[0003] A three-dimensional (3D) printer usually implements an additive manufacturing (AM) process to build an object layer by layer from a digital model. Additive Manufacturing of rubber is a novel and emerging 3D printing manufacturing technology for making a 3D object from rubber components based on a digital model. The 3D printer usually implements various filament-based approaches, such as Fused Filament Fabrication (FFF), that is also known under the brand name Fused Deposition Modeling (FDM). In particular, the 3D printer is configured to feed a thermoplastic material, such as rubber, in a filamentary form to a nozzle through an extruder, The rubber is heated and fused in the nozzle when the nozzle moves during a printing process. The nozzle moves along a section contour of a filling track and extrudes the heated and fused rubber. The rubber rapidly solidifies and condenses together with the surrounding material. The printing process is configured to be computer-controlled, manually controlled, orIM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248) both. As a result, the 3D printer is configured to implement multiple additive processes to lay down successive layers of rubber on top of each other.SUMMARY OF THE INVENTION

[0004] Disclosed herein is a method for three-dimensional (3D) printing rubber in a downhole device, such as a downhole mud motor or a downhole pump (e.g., Moineau pump). The method includes positioning a print head mounted on a heated feed line within the downhole device. The method further includes coupling the print head to an emitter mounted on the heated feedline. The method further includes connecting the print head to an external extruder for feeding rubber. The method further includes injecting the rubber through the print head at a first location of the housing of the downhole device and vulcanizing the rubber during printing. The method further includes solidifying the rubber before the print head is moved out of contact with the solidified portions of the rubber. The method further includes moving the print head to a second location of the housing of the downhole device. The print head is based on fused filament fabrication. The extruder may be optionally integrated with the print head in a single component; thus, the extruder is configured to be operated by an extruder drive using a universal shaft. Tire extruder extrudes the rubber into an equalizing chamber that is configured to use a piston to generate an equalized pressure for the extrusion of rubber for feeding the print head. A sensor is deposited at an inner wall of the equalizing chamber to monitor a pressure of the rubber near an outlet of the equalizing chamber. The printer head is configured to move up / down and rotate around the heated feed line inside the housing during printing. The movement of the printer head inside the device housing is determined by using an algorithm. The heated feed line is configured to move longitudinally inside the housing during printing. The emitter is a vulcanization device selected from a group consisting of an infrared heater, aIM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248) beta β⁻emitter, a microwave source, and a laser. The emitter is configured to transport radiation through a fiber to a printing area in the housing.

[0005] Also disclosed is a system for 3D printing rubber in a downhole device. The system includes an external extruder, a heated feed line, a print head, and an emitter. The external extruder is configured to extrude the rubber. The heated feed line is connected to the external extruder. The heated feed line is configured to extend longitudinally within a housing of the downhole device to feed the rubber extruded from the external extruder. The print head is mounted on the heated feed line within the downhole device. The print header is configured to inject the rubber at a first location of the housing of the downhole device, move out of contact with the solidified portions of the rubber after solidifying the rubber, and move to a second location of the housing of the downhole device. The emitter is mounted on the heated feedline. The emitter is configured to vulcanize the rubber in the print head during printing. The print head is based on fused filament fabrication. The extruder may be optionally integrated with the print head in a single component; thus, the extruder is configured to be operated by an extruder drive using a universal shaft. The extruder extrudes the rubber into an equalizing chamber that is configured to use a piston to generate an equalized pressure for the extrusion of rubber for feeding the print head. A sensor is deposited at an inner wall of the equalizing chamber to monitor a pressure of the rubber near an outlet of the equalizing chamber. The printer head is configured to move up / down and rotate around tire heated feed line inside the housing during printing. The movement of the printer head inside the device housing, and discharge of the polymer from the nozzle, is determined by using an algorithm. The heated feed line is configured to move longitudinally inside the device housing during printing. The emitter is a vulcanization device selected from a group consisting of an infrared heater, a beta / ? "emitter, a microwave source, and a laser. The emiter is configured to transport radiation through a fiber to a printing area in the device housing.-3- IM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248)BRIEF DESCRIPTION OF DRAWINGS

[0006] Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:

[0007] FIG, 1 is a side schematic view of an example of a 3D printer extruding rubber using an external extruder in an additive manufacturing (AM) process.

[0008] FIG, 2 is a side schematic view of an example of a 3D printer extruding rubber using an internal extruder integrated with a print head as one part.

[0009] FIG, 3 is a side sectional schematic view of an example of a pressure equalizer for rubber extrusion.

[0010] FIG. 4 is a side schematic view of an example of a 3D printer with inline vulcani zation.

[0011] FIG. 5 is a side-sectional schematic view of an example of a 3D printer of rubber in a housing,

[0012] FIG. 6 is a functional block diagram of a computer system.

[0013] While subject matter is described in connection with embodiments disclosed herein, it ■will be understood that the scope of the present disclosure is not limited to any particular embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents thereof.DETAILED DESCRIPTION OF INVENTION

[0014] The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown.-4- IM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248) The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout. In an embodiment, usage of the term “about” includes t- / - 5% of a cited magnitude. In an embodiment, the term “substantially” includes + / - 5% of a cited magnitude, comparison, or description. In an embodiment, usage of the term “generally” includes + / - 10% of a cited magnitude.

[0015] It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation.

[0016] In a side schematic view in FIG. 1 is an example of a 3D printer 100 extruding rubber using an external extruder in an additive manufacturing (AM) process. 3D printer 100 in this example is configured to implement a fused filament fabrication (FFF) technology for an extrusion system that includes a cold end component and a hot end component for rubberizing a downhole device with a filament, such as a thermoplastic rubber material. Examples of the downhole device include a mud motor and a downhole pump, such as a progressing cavity pump or a Moineau pump, The cold end component is a power part including extruder 102 that is responsible for the extrusion and withdrawal of the filament and the movement of the filament in the hot end component. The hot end component includes a print head 106 that includes heat sink, fan, and nozzle, that are responsible for completing the heating, printing,-5- IM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248) and cooling of the filament in the AM process. Alternative embodiments include a heater (not shown) in the extruder 102 for heating rubber inside. Traditional methods usually use various molds for rubberizing a downhole device, which limits flexibility because the molds are fixed. The application of the standard fused filament fabrication (FFF) process is highly challenging for items used in a downhole environment due to extreme downhole conditions and limitations. Downhole devices usually operate in highly demanding environments with high temperature, high pressure, and corrosive drilling fluids. The filament needs to have enough durability and tear strength to operate properly in the downhole environment. Examples of an adequate rubber compound include nitrile rubber (NBR) and hard rubber (HR) for the filament to print in the housing of the downhole device. However, due to the nature of the thermo-plastic rubber material, there are some issues with directly 3D printing rubber in the housing. In particular, a large and heavy extruder is needed for extruding rubber. As another example, inhomogeneous rubber deposition is the result of pressure variations during the extrusion process, and nonvulcanized rubber exhibits inadequate stability for the FFF process. Thus, it is desirable to develop an improved 3D printing method for printing rubber in the downhole device housing for highly challenging downhole environments.

[0017] In some embodiments, in a traditional 3D printer, an extruder is mounted on a gantry system to provide precise, multi-axis movement for material deposition. However, the gantry system usually slows down the printing process and involves a complex setup and the extruder drive, extruder 102, and nozzle have a combined mass that is difficult to move quickly. To solve the issue of a large and heavy extruder, 3D printer 100 is configured to implement external extruder 102, for feeding rubber to print head 106, through a heated and high-pressure-stable hose 104. In particular, the heated hose 104 is a specialized heated hose operating at 90 degrees Celsius (°C) that is configured to deliver fast ramp-up and precise temperature control for a constant flow of the filament from extruder 102 to print head 106. In examples, hose 104-6- IM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248) is heated from heat tape or circulating fluids (not shown), and the extruder 102 and print head 106 are heated using a heating cartridge (not shown). Shown in FIG. 1 is a product 108 created with the printer 100, examples of the product 108 include a stator for use in a downhole mud motor, alternatively, product is a stator for use in a Moineau pump. In an embodiment of the present disclosure, a gantry system (not shown) is employed for strategically positioning the print head 106 so that filament is deposited at designated locations to form the product 108 as designed. Gantry includes a framework of horizontal and vertical axes commonly in the x-, y-, and z-directions, and allows a movement of an end effector on which the print head 106 is mounted and translated along these axes. Up to three rotating axes (e.g., A, B, and C) are optionally mounted on the end effector or a bed of the gantry’, which rotate the mountpoint at tire end effector or the mountpoint on the bed of tire gantry system along the axes. In another alternative, the device in w'hich the product 108 is being formed is rotated about a main axis, and the gantry’ moves the print head 106 along the main axis (x-axis) and compensates for the distance to the base geometry (z-direction) - this creates a three-axis system having an x-axis, an orbital path around the x-axis, and the height to the base geometry is compensated by the z axis. In a non-limiting example, the print head 106 movement is controlled by an algorithm written in geometric code (“g-code"’) such as RS-274 and standardized in ISO-6983. Using this protocol, the print head 106 moves from point to point along a substantially straight line. Tire path generation and the g-code creation are optionally handled in a pre-processing or slicing step and handled by a preprocessing software also known as slicer. The 3D model of the part is loaded into the slicer software and pre-defined parameters and path generation strategies are allocated, tire 3D printer controller readable code is then created by the software, examples of the readable code include a g-code.

[0018] A side schematic view of an example of a 3D printer 200 is shown in FIG. 2, in which 3D printer 200 is configured to extrude rubber using an internal extruder integrated with a print IM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248) head as one part. In this example, 3D printer 200 includes an extruder 202, a universal shaft 204, a print head 206, and an extruder drive 208. Extruder 202 and print head 206 are integrated into a single component that is coupled to extruder drive 208 via universal shaft 204, Extruder 202 is configured to work in conjunction with extruder drive 208 that is configured to control the rate that pushes and pulls filament into one or more filament tubes, reducing a load on a drive gear of the extruder 202. Thus, extruder drive 208 provides a supply-side drive system for automatic loading of filament, swapping of filament, and multi-filament extrusion for extruder 202. For example, extruder drive 208 includes a rotary drive gear that is configured to rotate in a first direction to advance a first filament toward a first extrusion opening associated with print head 206. Likewise, the rotary’ drive gear is configured to rotate in a second direction to advance a second filament toward a second extrusion opening associated with print head 206. Thus, the rotary drive gear of extruder drive 208 is coupled to a remote motor of extruder 202 by transmitting torque and rotation motion between misaligned shafts using universal shaft 204. Embodiments of the shaft 204 include a cable-like flexible member that is elongated, but with adequate structural integrity for transmitting a rotational torque. In alternatives, the shaft 204 is made up of segments connected end to end with flexible joints to form an articulated element. Separating the print head 206 and extruder drive 208 allows for faster and more precise movement of the print head 206, reduces the time and force required to create a formed product, and the formed product is as designed. Shown in FIG. 2 is a product 210 created with the printer 200, examples of the product 210 include a stator for use in a downhole mud motor, alternatively, product is a stator for use in a Moineau pump.

[0019] A side sectional schematic view of an example of a pressure equalizer 300 is shown in FIG. 3, in which pressure equalizer 300 is configured to compensate for pressure fluctuations that occur during rubber extrusion. Pressure equalizer 300 includes an equalizing chamber 302, a piston 304, and one or more pressure sensors 310. Equalizing chamber 302 includes an inlet -8- IM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248) opening 306 to receive a filament, such as rubber, from a first hose connected to an extruder and an outlet opening 308 to extrude the filament with an equalized pressure to a second hose connected to a print head. For example, the filament is molten or having a low viscosity when entering the equalizing chamber, and is a void free thermoplastic raw material that includes one or more axial fiber strands extending within a matrix material of the filament. Upon receiving the feeding filament from inlet opening 306, pressure equalizer 300 is configured to use the one or more pressure sensors 310 attached to the inner walls of equalizing chamber 302 to monitor a pressure change due to the load of tlie feeding filament. Pressure equalizer 300 is configured to move piston 304 in response to the pressure changes in the equalizing chamber 302, in examples the equalizer 300 adjusts filament pressure in the chamber 302 at a frequency that ranges from about 1 Hz to about 10 Hz, embodiments include frequencies above or below this range as pressure fluctuations are dependent on the particular extruder as well as material properties of the filament. For example, pressure equalizer 300 is configured to move piston 304 a designated distance into chamber 302 to compensate for a particular pressure fluctuation drop measured in the equalizing chamber 302, and is configured to move piston 304 a designated distance out of chamber 302 to compensate for a particular pressure fluctuation increase measured in the equalizing chamber 302. As a result, the pressure changes in filament are substantially reduced when piston 304 moves in the chamber to adjust the pressure. The one or more pressure sensors 310 monitor the pressure, where the pressure value is used for controlling the movement of piston 304, The print head improves the printing result in an AM process by using homogeneous extrusion of the filament at outlet opening 308 of equalizing chamber 302. In alternatives, the chamber 302 is included in the embodiments of FIG. 1, FIG.2, or both.

[0020] A side schematic view of an example of a 3D printer 400 is shown in FIG. 4, in which 3D printer 400 is configured to implement vulcanization of rubber during printing. For 3D -9- IM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248) printer 400. a print head 106 is configured to receive a filament, such as a fused rubber material, extruded from a remote extruder 102 through a heated hose 104. Print head 106 moves along a section contour of a filling track and extrudes the filament. The extruded material rapidly solidifies and condenses together with the surrounding material. Print head 106 is coupled to an emitter 402 for vulcanization of rubber during printing. Non-vulcanized printed rubber shows low stability and limits the geometrical features. For example, emitter 402 is an infrared heater, a β emitter, a microwave source, a laser, and combinations. In particular, emitter 402 is optionally placed outside 3D printer 400, and the radiation is transported through fibers or hollow waveguides to a printing area. Therefore, 3D printer 400 has the advantage of depositing uncured rubber and then curing the rubber with an emitter included with the print head in a single step process. In FIG. 4, the emitter 402 is mounted to a side of print head 106, other embodiments exist, such as a ring shaped infrared heater or laser arranged in a ring profile circumscribing the print head 106. In alternatives, the emitter 402 is included in the embodiments of FIG. 1, FIG. 2, or both. Shown in FIG. 4 is a product 408 created with the printer 400, examples of the product 408 include a stator for use in a downhole mud motor, alternatively, product is a stator for use in a Moineau pump.

[0021] A side sectional schematic view of an example of a 3D printer 500 is shown in FIG.5, in which 3D printer 500 is configured to print rubber directly in a housing 510. 3D printer 500 includes an extruder and actuator component 502, a rigid heated feed line 504, a print head 506, and an emitter 508. For example, 3D printer 500 is configured to inject a polymer, such as a thermo-plastic rubber material, through print head 506 into an annular space 512 defined between print head 506 and an inner surface 518 of a tubular, such as a housing 510 that is being lined.-10- IM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248)

[0022] In some embodiments, the extruder and actuator component 502 includes an extruder for extruding the polymer through the rigid heated feed line 504 that is configured to sustain high pressure when depositing print head 506 to a first printing area inside the housing 10. In particular, the extruder is coupled to a pressure equalizer to equalize the pressure of the polymer before it is fed into the rigid heated feed line 504. Likewise, the extruder and actuator component 502 includes an actuator that is communicatively coupled to print head 506 mounted at one end of the rigid heated feed line 504 inside the housing 510, thus enabling print head 506 to move up / down and rotate around the heated feed line 504 with high precision. The rigid feed line 504 is configured to feed the polymer to print head 506 and provide a longitudinal movement for print head 506 in the housing 10. Emitter 508 is mounted next to print head 506 on the rigid heated feed line 504 in the housing 510. In particular, emitter 508 is coupled to print head 506 for vulcanization of the polymer during printing, with the radiation transported through fibers or hollow waveguides to the first printing area inside the housing 510. For example, emitter 508 is an infrared heater, a β emitter, a microwave source, a laser, and combinations.

[0023] In some embodiments, print head 506 includes at least one nozzle that is configured to inject a filament made from the polymer to leave a layer of the polymer a full 360 degrees around printhead 506 against the inner surface 518 of the housing 510 of a downhole device. For example, the downhole device is a mud motor or a progressive cavity pump (e.g., a Moineau pump), and the product 516 being formed is a stator for the mud motor or the progressive cavity pump. Likewise, print head 506 is longitudinally movable in the direction 514 relative to the housing 510 while the polymer is being injected. The polymer rapidly solidifies and condenses together with the surrounding material before print head 506 moves away from the first print area to a second print area inside the housing 510. Print head 506 is configured to inject the polymer while it moves along a section contour of a filling track. Thus,-11- IM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248) an inner surface of the polymer has a profile defined by an outer surface of print head 506. Therefore, 3D printer 500 is configured to implement the FFF technology for manufacturing complex rubber geometries without a mold and directly printing rubber in the housing of the downhole device by extruding rubber in an AM process, equalizing rubber extrusion, and inline vulcanization, which enables additive manufacturing of rubber components in the downhole device. Alternatives of printer 500 include configurations the same or similar to that printer 100 of FIG. 1 and printer 200 of FIG. 2, and in examples of compact extruders and / or extruder drives, they are combined and moved with the print head 506. In this embodiment, feedline is limited to a rubber compound, which is easier to convey to the extruder than rubber that is molten.

[0024] FIG. 6 is a functional block diagram of a computer system (or “system”) 600 in accordance with one or more embodiments. In some embodiments, system 600 is a programmable logic controller (PLC). System 600 may include memory 604, processor 606, and input / output (I / O) interface 608. Memory 604 may include non-volatile memory (for example, flash memory, read-only memory (ROM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM)), volatile memory (for example, random access memory (RAM), static random access memory' (SRAM), synchronous dynamic RAM (SDRAM)), or bulk storage memory (for example, CD-ROM or DVD-ROM, hard drives). Memory 604 may include a non-transitory computer-readable storage medium (for example, a non-transitory program storage device) having program instructions 610 stored thereon. Program instructions 610 may include program modules 612 that are executable by a computer processor (for example, processor 606) to cause the functional operations described, such as those described with regard to 3D printer 100, 3D printer 200, pressure equalizer 300, 3D printer 400, or 3D printer 500.-12- IM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248)

[0025] Processor 606 may be any suitable processor capable of executing program instructions. Processor 606 may include a central processing unit (CPU) that carries out program instructions (for example, the program instructions of the program modules 612) to perform the arithmetical, logical, or input / output operations described. Processor 606 may include one or more processors. I / O interface 608 may provide an interface for communication with one or more I / O devices 614, such as a joystick, a computer mouse, a keyboard, or a display screen (for example, an electronic display for displaying a graphical user interface (GUI)). I / O devices 614 may include one or more of the user input devices. I / O devices 614 may be connected to I / O interface 608 by way of a wired connection (for example, an Industrial Ethernet connection) or a wireless connection (for example, a Wi-Fi connection). I / O interface 608 may provide an interface for communication with one or more external devices 616. In some embodiments, I / O interface 608 includes one or both of an antenna and a transceiver. In some embodiments, external devices 616 include logging tools, lab test systems, well pressure sensors, well flowrate sensors, or other sensors described in connection with pressure equalizer 300.

[0026] Further modifications and alternative embodiments of various aspects of the disclosure will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the embodiments. It is to be understood that the forms of the embodiments shown and described herein are to be taken as examples of embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed or omitted, and certain features of the embodiments may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the embodiments. Changes may be made in the elements described herein without departing from the spirit and scope of the em bodiments as described -13- IM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248) in the following claims. Headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description.

[0027] It will be appreciated that the processes and methods described herein are example embodiments of processes and methods that may be employed in accordance with the techniques described herein. The processes and methods may be modified to facilitate variations of their implementation and use. The order of the processes and methods and the operations provided may be changed, and various elements may be added, reordered, combined, omitted, modified, and so forth. Portions of the processes and methods may be implemented in software, hardware, or a combination of software and hardware. Some or all of the portions of the processes and methods may be implemented by one or more of the processors / modules / applications described here.

[0028] As used throughout this application, the word “may” is used in a permissive sense (that is, meaning having the potential to), rather than the mandatory sense (that is, meaning must). The words “include,” “including,” and “includes” mean including, but not limited to. As used throughout this application, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly indicates otherwise. Thus, for example, reference to “an element” may include a combination of two or more elements. As used throughout this application, the term “or” is used in an inclusive sense, unless indicated otherwise. That is, a description of an element including A or B may refer to the element including one or both of A and B. As used throughout this application, tire phrase “based on” does not limit the associated operation to being solely based on a particular item. Thus, for example, processing “based on” data A may include processing based at least in part on data A and based at least in part on data B, unless the content clearly indicates otherwise. As used throughout this application, the term “from” does not limit the associated operation to being directly from.-14- IM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248) Thus, for example, receiving an item “from” an entity may include receiving an item directly from the entity or indirectly from the entity (for example, by way of an intermediary entity). Unless specifically stated otherwise, as apparent from the discussion, it is appreciated that throughout this specification discussions utilizing terms such as “processing,” “computing,” “calculating,” “determining,” or the like refer to actions or processes of a specific apparatus, such as a special purpose computer or a similar special purpose electronic processing / computing device. In the context of this specification, a special purpose computer or a similar special purpose electronic processing / computing device is capable of manipulating or transforming signals, typically represented as physical, electronic or magnetic quantities within memories, registers, or other information storage devices, transmission devices, or display devices of the special purpose computer or similar special purpose electronic processing / computing device.10029] At least one embodiment is disclosed and variations, combinations, modifications of the embodiment(s), or features of the embodiment(s) made by a person having ordinary skill in the art are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, or omitting features of the embodiment(s) are also within the scope of the disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations may be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (for example, from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). The use of the term “about” (or its variants) means ±10% of the subsequent number, unless otherwise stated.

[0030] Use of the term “optionally” with respect to any element of a claim means that the element is required, or alternatively, the element is not required, both alternatives being within the scope of the claim. Use of broader terms such as comprises, includes, and having may be-15- IM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248) understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of. Accordingly, the scope of protection is not limited by the description set out above but is defined by the claims that follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present disclosure.

[0031] While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods might be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted, or not implemented. In an example, the extruder 102 is fed with filament-like feedstock material sometimes referred to as strips (not shown) that are stored proximate the extruder 102. The extruder 102 pulls in the strips automatically, and when fully used, additional strips are fed into the extruder 102.

[0032] In addition, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other sy stems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as coupled or directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component whether electrically, mechanically, or otherwise.

[0033] Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the subject matter of the present disclosure therefore should be determined with reference to the appended claims, along with the full scope of equivalents -16- IM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248) to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.”-17- IM-#J0849864.7

Claims

Attorney Docket No.: 65DHM-510991-WO-2 (000248)CLAIMSWhat is claimed is.

1. A method for three-dimensional (3D) printing rubber in a downhole device, comprising:positioning a print head mounted on a heated feed line within the downhole device; coupling the print head to an emitter mounted on the heated feedline;connecting the print head to an external extruder for feeding rubber;injecting the rubber through the print head at a first location in a housing of the downhole device and vulcanizing the rubber during printing;solidifying the rubber before the print head is moved out of contact with the solidified portions of the robber; andmoving the print head to a second location of the housing.

2. The method of claim 1, wherein the downhole device is selected from the group consisting of a mud motor and a pump.

3. The method of claim 1, wherein the extruder extrudes the rubber into an equalizing chamber that is configured to use a piston to generate an equalized pressure for extrusion of rubber for feeding the print head.

4. The method of claim 3, wherein a sensor is deposited at an inner wall of the equalizing chamber to monitor a pressure of the rubber near an outlet of the equalizing chamber.

5. The method of claim 1, wherein the printer head is configured to move up and down and rotate around the heated feed line inside the housing during printing.

6. The method of claim 1, wherein the movement of the printer head inside the housing is determined by using an algorithm.

7. The method of claim 1, wherein the heated feed line is configured to move longitudinally inside the housing during printing.

8. The method of claim 1, wherein the emitter is a vulcanization device selected from a group consisting of an infrared heater, a beta ^“emitter, a microwave source, and a laser.

9. The method of claim 8, wherein the emitter is configured to transport radiation through a medium to a printing area in the housing, wherein the medium is selected from the group consisting of a fiber and a hollow waveguide.-18- IM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248)10. The method of claim 1, wherein the extruder is integrated with the print head in a single component, the extruder configured to be operated by an extruder drive using a universal shaft.

11. A system for three-dimensional (3D) printing rubber in a downhole device, comprising:an external extruder configured to extrude the rubber;a heated feed line connected to the external extruder, the heated feed line configured to extend longitudinally within a housing of the downhole device to feed the rubber extruded from the external extruder;a print head mounted on the heated feed line within the downhole device, the print header configured to inject the rubber at a first location of the housing of the downhole device, move out of contact with the solidified portions of the rubber after solidifying the rubber, and move to a second location of the housing of the downhole device; andan emitter mounted on the heated feedline, the emitter configured to vulcanize the rubber in the print head during printing.

12. The system of claim 11, wherein the downhole device is selected from the group consisting of a mud motor and a pump.

13. The system of claim 11, wherein the extruder extrudes the rubber into an equalizing chamber that is configured to use a piston to generate an equalized pressure for extrusion of rubber for feeding the print head,14. The system of claim 13, wherein a sensor is deposited at an inner wall of the equalizing chamber to monitor a pressure of the rubber near an outlet of the equalizing chamber.

15. The system of claim 11, wherein the printer head is configured to move up and down and rotate around the heated feed line inside the housing during printing.

16. The system of claim 11, wherein the movement of the printer head inside the housing is determined by using an algorithm.

17. The system of claim 11, wherein the heated feed line is configured to move longitudinally inside the housing during printing.

18. The system of claim 11, wherein the emitter is a vulcanization device selected from a group consisting of an infrared heater, a beta β⁻ emitter, a microwave source, and a laser.-19- IM-#J0849864.7Attorney Docket No.: 65DHM-510991-WO-2 (000248)19. The system of claim 18, wherein the emitter is configured to transport radiation through a medium to a printing area in the housing, wherein the medium is selected from the group consisting of a fiber and a hollow waveguide.

20. The system of claim 11, wherein the extruder is integrated with the print head in a single component, the extruder configured to be operated by an extruder drive using a universal shaft.-20- IM-#J0849864.7

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