Additive Casing Liner Printing for Consistent Wellbore Integrity

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Solution Overview

Problem

Traditional casing operations in wells face issues with structural integrity due to inconsistent cement placement, leading to voids and potential fractures, and are time-consuming and costly with a stop-start approach.

Innovation Solution

Employ additive manufacturing techniques, such as 3D printing, to precisely deposit cementitious materials in the wellbore, forming a casing liner with integrated structures that enhance mechanical properties and reduce inconsistencies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional cement placement methods are used, then the process is simpler and faster to implement, but the structural integrity deteriorates due to inconsistent cement placement creating voids and potential fractures

Engineering Contradiction:

Improvestructural integrityVSAvoidcement placement consistency

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent changes the placement parameters of cement from bulk pouring to precise additive deposition, controlling the amount, location, and distribution of cement material to eliminate voids and ensure consistent placement throughout the annular space

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces traditional mechanical cement placement systems with additive manufacturing technology, using controlled material ejection and deposition mechanisms to achieve precise cement placement without the inconsistencies of conventional methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If traditional stop-start casing operations are used, then the process is easier to manage, but the productivity deteriorates due to time-consuming operations and increased costs

Engineering Contradiction:

Improveoperation speedVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent enables continuous additive manufacturing of the casing liner as the wellbore is being drilled, eliminating stop-start operations and maintaining continuous productive action throughout the well construction process

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent performs preliminary additive manufacturing of the casing liner material directly in the wellbore during drilling operations, preparing the structural component in advance rather than requiring separate installation operations later

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Ensures precise cement deposition and integrated structures that enhance ductility and impact resistance, improving structural integrity while reducing time and costs by allowing continuous operations.

Implementation Method 1

additive manufacture of a casing liner in an annular region between an exterior of a casing pipe positioned in a wellbore and a wall of the wellbore

Methodology Applied

Scientific Effect3D Printing: 3D Printing

Data Source

PatentUS12442272B2Additive manufacture of casing liner in a wellbore

Publication Date: 2025.10.14 SAUDI ARABIAN OIL CO

AI summary

Provided are systems and methods for forming a casing liner in a wellbore of a hydrocarbon well. The forming including disposing a casing liner print head in an annular region located between a casing pipe disposed in a wellbore of a hydrocarbon well and a wall of the wellbore, and conducting a downhole lining operation including operating the casing liner print head to eject casing liner material into the annular region to form, in the annular region, a casing liner including elongated voids formed in the casing liner material.