Scaling AM in Oil and Gas: From Prototyping to the Digital Supply Chain

APRIL 07, 2026 | Reading time: 5 min

The oil and gas industry often conjures images of massive steel structures, heavy castings, and legacy hardware that has operated for decades. At ExxonMobil’s Baton Rouge refinery, some compressors have been running since 1938. However, beneath the surface of these traditional operations, a digital revolution is taking hold. Christopher Beeson, the Special Purpose Machinery Execution Supervisor and Additive Manufacturing (AM) Lead for Baton Rouge, is at the forefront of this shift. With over 30 years of experience, starting in manual welding, Beeson understands the physical reality of metal. He now spends his days championing a future where spare parts exist primarily as digital files in the cloud.

ExxonMobil is moving past the experimental phase of 3D printing. The company is transitioning from centralized corporate research labs to a distributed, site-led model where individual refineries "go and do." This evolution marks a significant turning point for the sector, proving that AM is now a critical tool for maintaining global energy infrastructure.

The Strategic Shift From Corporate Labs to Site Execution

ExxonMobil began its journey with centralized AM labs in Houston, Texas, and Clinton, New Jersey. These facilities focused on non-metals and early prototyping. While these labs provided a necessary foundation, the real value of AM lies in the field. The introduction of the API 20S standard in 2021 served as the primary catalyst for change. This standard provided the first major framework for additively manufactured metallic components in the oil and gas industry.

Once API 20S established a path for qualification, ExxonMobil realized that Laser Powder Bed Fusion (LPBF) had surpassed the density and reliability of traditional casting. The technology reached a level of maturity that allowed corporate headquarters to hand the reins to individual sites. "Scaling additive is my job," Beeson says, noting that the focus has shifted to North American and Singapore sites where the demand for immediate, high-quality parts is greatest.

Killing the Inventory Tax Through Digital Supply Networks

The financial driver behind scaling AM is the reduction of "inventory tax." Oil and gas giants spend billions of dollars every year storing physical parts that they might never use. One internal study on pump impellers revealed that 40% of stocked units were eventually scrapped or never put into service because engineers rerated pumps or replaced entire systems. By moving to a digital supply network, ExxonMobil can eliminate the need for massive physical warehouses.

To achieve this, ExxonMobil collaborates with competitors like Shell and ConocoPhillips through an industry-wide "digital cloud" known as Field Node. In this environment, companies share non-proprietary 3D files. If a common pump volute fails, an engineer can check the cloud to see if another company has already scanned and qualified the part. This collaboration allows ExxonMobil to skip the expensive reverse-engineering phase and move straight to production. A trusted network of audited print shops, including Oerlikon and Quintus, stands ready to print these parts on demand.

Mature Technologies and Emerging Frontiers

While LPBF remains the mature standard for complex, dense components like impellers, other technologies are quickly gaining ground. Wire Arc Additive Manufacturing (WAAM) and Directed Energy Deposition (DED) represent growing areas for the industry. These methods are ideal for replacing large, legacy cast-iron components that often stand 4 to 5 feet tall.

Traditionally, procuring a large casting could take 12 to 14 months. With industrial 3D printing, refineries can produce a functional replacement in a matter of weeks. ExxonMobil also continues to push the boundaries of materials. Through collaborations with partners like Sandvik, the company develops proprietary powders specifically designed for harsh refinery environments, such as pyrolysis furnaces.

Beeson argues that LPBF is "supremely superior" to casting, suggesting that the industry only clings to traditional methods because of familiarity rather than performance.

Solving the Workforce Challenge Through Local Partnerships

Scaling technology requires a skilled workforce, yet most mechanical engineers at legacy sites have little experience with additive design. Furthermore, the industry currently lacks a formal "union craft" for 3D printer technicians. To bridge this gap, ExxonMobil helps lead the Louisiana Additive Manufacturing Association (LAMA). This partnership aims to build a Center of Excellence (COE) in Baton Rouge.

The COE serves as a "three-in-one" tool for the region. It provides ExxonMobil engineers with hands-on training, gives the site access to industrial-grade printers, and drives economic development. Students from local universities, such as LSU, can certify on various printer brands like EOS and Velo3D. This makes them immediately hirable in the growing manufacturing sector.

The economics of the partnership are also compelling. High-level LAMA membership offers 5,000 free print hours, which can reduce the cost of a $16,000 impeller to just the price of the powder.

Overcoming the Digital Readiness Bottleneck

Despite the progress, a significant "workflow gap" remains the primary bottleneck to total adoption. Moving from a raw 3D scan to a printer-ready file requires answering dozens of technical questions regarding surface finish, testing protocols, and post-processing. To solve this, the International Association of Oil and Gas Producers (IOGP) launched the Joint Industry Sprint (JIS O2).

This initiative creates a "Digital Passport" for parts using Digital Readiness Levels (DRL). A DRL 1 part contains basic scan data and material tests, while a DRL 3 part is a complete digital package. It includes inspection plans and roughness specifications.

The ultimate goal is a "one-button" request for quote (RFQ) system. When the digital package is complete, the site lead simply hits a button to send the specifications to a qualified vendor, removing weeks of administrative back-and-forth.