Leveraging Robotic Large Format Additive Manufacturing (LFAM) to Introduce Post-Industrial Recycled Polymers and Composites into the Production of New Applications in the Energy Sector On-Site

Abstract Large Format Additive Manufacturing has been supporting the introduction of more sustainable and efficient part production on-site for the energy players. From 3D printing simulacra on-demand in remote locations to developing new applications in a more flexible manner, Large Format Additive Manufacturing has been supporting innovation for the Oil & Gas sector. Over the last five years, robotic Large Format Additive Manufacturing has emerged as a leading technology for the fabrication of complex, lightweight, and high performing parts across sectors, where the volume is above 1 m3. The possibility of fabricating large monolithic parts allows to introduce great benefits to manufacturing supply chains – making the innovation relevant on applications that range from tooling to finished parts in advanced sectors such as Aerospace, Automotive, and Energy. Specifically, thanks to the fast production lead times, the drastic reduction of direct human intervention for assembly and reworking, and the ability to combine both process cost-efficiencies and environmental sustainability the Oil & Gas sector has significantly grown its interest on the technology, particularly to produce several components locally and on-demand. Leading companies in the sector have been working to introduce certifiable sustainable materials, often also underdoing metal replacement, for the production of several applications: from non-critical parts to functional parts such as piping and plant components; all done with a more efficient and sustainable manufacturing process - robotic large format additive manufacturing. Through several research and customer projects, Large Format Additive Manufacturing technology companies have been collaborating with leading players in the Energy sector to validate real-world applications, gradually moving from lower risk parts to researching on higher-risk applications. Specifically, what has already been proven are a series of applications that include buildings and site facilities as well as simulacra and temporary spare parts produced on-demand.