The Challenge

Energy-sector components are traditionally constrained by long lead times, complex geometries, and conservative qualification pathways.

For ExxonMobil, the challenge was not simply producing a part additively—but demonstrating that metal AM could deliver:

• Robust material performance under demanding operating conditions
• Repeatable manufacturing quality
• Design freedom without compromising reliability
• A viable path toward industrial adoption

The Approach

Using Nikon SLM Solutions’ industrial laser powder bed fusion technology, the collaboration focused on producing metal components that meet the functional and operational expectations of the energy sector.

The project leveraged:

• Proven LPBF process stability
• Design freedom enabled by additive manufacturing
• Controlled, repeatable build strategies suitable for industrial environments

Rather than chasing experimental complexity, the emphasis was placed on manufacturability, robustness, and consistency—key requirements for real-world energy applications.

The Result

The collaboration demonstrated how metal additive manufacturing can support energy-sector requirements by enabling:

• Complex internal geometries not feasible with conventional manufacturing
• Reduced assembly complexity through part consolidation
• Shortened development cycles
• A clearer pathway toward qualification and deployment

The outcome reinforces metal AM’s role as a production-capable manufacturing technology, not just a development tool.

Why It Matters

For the energy industry, additive manufacturing is most valuable when it delivers measurable benefits without introducing unnecessary risk.

This case study shows how industrial-scale metal AM can:

• Support innovation while maintaining operational confidence
• Enable design optimization aligned with real service conditions
• Complement existing manufacturing strategies rather than replace them outright

It reflects a broader shift toward pragmatic adoption of additive manufacturing—focused on performance, reliability, and long-term value.