ExxonMobil's 3D Printing Innovation Cuts Costs and Time

ExxonMobil's 3D Printing Breakthrough Reduces Production Costs and Lead Times in Louisiana Refinery \\[n]In the heart of Louisiana, ExxonMobil's Baton Rouge refinery faced a recurring challenge: protecting instrument cabinets from oil contamination. The solution, an anti-wicking device, was expensive and time-consuming to produce using traditional machining methods. By adopting Meltio’s wire-based Laser Metal Deposition (LMD) system, the M600, ExxonMobil significantly cut both production costs and lead times. This innovative approach not only made titanium parts economically viable but also set a new benchmark for efficiency. \\[n]### Why Titanium and the Challenges It Posed \\[n]Titanium 64, known for its lightweight and cost-effectiveness, was chosen as the material for the anti-wicking device. However, printing with titanium introduced several challenges. The alloy requires an inert atmosphere during deposition, necessitating 90 minutes of purging before each build. Additionally, a minimum of seven minutes between layers was required to prevent thermal buildup, making single-part runs impractical. Early trials revealed issues such as surface oxidation, material accumulation, and physical displacement of unanchored components. \\[n]### Redesigning the Process for Additive Manufacturing \\[n]To overcome these challenges, ExxonMobil’s engineers reworked the part design from the ground up. A custom fixture, printed from stainless steel, allowed four components to be produced simultaneously, extending dwell times and eliminating oxidation. The main body was redesigned within a 75-degree overhang limit, and a non-planar deposition strategy was used to remove the need for support structures. The lid was modified to include hollow perimeters for silicone sealant retention. By selectively reducing laser power and print speed in areas prone to overgrowth and adding mechanical clamps, the team produced a solid, leak-proof titanium barrier that met the refinery’s strict reliability requirements. \\[n]### Outcomes and Implications for ASEAN Factories \\[n]The shift from subtractive to additive manufacturing reduced the per-unit cost by 42% and compressed lead times from four to six weeks down to just 58.8 hours. This significant improvement has profound implications for factories in Thailand, Vietnam, Indonesia, and Malaysia. In these countries, where manufacturing is a key economic driver, the ability to produce complex titanium components at a lower cost and in a shorter time frame can enhance competitiveness and operational efficiency. \\[n]For Thai factories, this means the potential to reduce production costs and improve product quality, especially in industries like automotive and electronics. Vietnamese manufacturers can leverage this technology to meet the growing demand for high-quality, cost-effective products. In Indonesia, where the manufacturing sector is rapidly expanding, the adoption of 3D printing can help streamline production processes and reduce logistical dependencies. Malaysian factories, known for their advanced manufacturing capabilities, can further enhance their competitive edge by integrating 3D printing into their operations. \\[n]### Conclusion \\[n]The success of ExxonMobil’s 3D printing initiative demonstrates the transformative potential of additive manufacturing in the industrial sector. For factory buyers in ASEAN, the key takeaway is the importance of embracing new technologies and redesigning components for additive manufacturing. By doing so, they can achieve significant cost savings, reduce lead times, and improve overall operational efficiency. As the region continues to grow, the adoption of 3D printing will be crucial in maintaining a competitive edge in the global market.