[Source:3D Criar]
Charles R. Goulding and Andressa Bonafe explore Petrobras’ innovative LABi3D and its transformative partnership with 3DCRIAR, setting new benchmarks for 3D printing in the energy industry.
Petróleo Brasileiro S.A. (Petrobras), a state-owned multinational founded in 1953, is Brazil’s largest company, with an annual revenue of USD 102.4 billion and more than 40,400 employees. Operating in 14 countries, Petrobras stands out for its activities in the exploration, production, and distribution of oil and gas across various business sectors.
Recently, Petrobras took a significant step toward innovation by inaugurating LABi3D at its Research Center (Cenpes) in Rio de Janeiro, solidifying its position as a leader in additive manufacturing in Latin America. This cutting-edge laboratory aims to tackle complex industrial challenges with a focus on efficiency and sustainability. The project involves collaboration with 3DCRIAR, a pioneering provider of additive manufacturing solutions that is recognized for its 3D as a Service® (3DaaS®) model. Among 16 proposals reviewed by Petrobras, 3DCRIAR was selected for its business vision that integrates technological innovation with corporate strategy, making it the ideal solution for LABi3D’s demands.
The 3D as a Service® model refers to an outsourcing system for additive manufacturing that allows companies to delegate both the management and operation of complex 3D printing systems. This approach also helps identify strategic opportunities, optimize costs, reduce lead times, and improve operational efficiency. For Petrobras, the 3DaaS® alternative is particularly appealing due to its ability to significantly lower the costs associated with on-demand production of parts, potentially reducing the need for large physical inventories. Moreover, it facilitates the rapid creation of prototypes and replacement parts, meeting the demands of complex and urgent projects in the oil and gas sector. Another notable advantage is the model’s flexibility, which enables the incorporation of technological advancements quickly without requiring high upfront investments in infrastructure or workforce training.
In the oil and gas industry, additive manufacturing plays a strategic role by enabling on-demand production of customized parts and critical components, significantly reducing downtime and operational costs. Technologies such as metal 3D printing allow for the production of heat- and corrosion-resistant parts, essential for operations in extreme environments. Additionally, the ability to quickly prototype fosters innovation in the design of tools and equipment. The adoption of additive manufacturing not only improves operational efficiency but also enhances the resilience of supply chains by reducing dependency on external suppliers of specialized items.
At LABi3D, certain equipment stands out, including the UltiMaker Factor 4, ideal for complex parts, the Formlabs Fuse 1+, which utilizes SLS technology, and the miniFactory Ultra 2, which uses advanced materials such as PEEK. The laboratory also employs cutting-edge 3D scanning tools and Siemens’ integrated digital twins and inventory systems, further amplifying its positive impact on the company’s operations and sustainability initiatives.
In 2019, we published an interview with Daniel Huamani, CTO of 3DCRIAR, in which he discussed the company’s vision for the future of 3D printing in Brazil. At the time, he presented 3DCRIAR’s goal of increasing access to additive manufacturing in Brazil, giving several examples of the company’s work on education, manufacturing, and healthcare. He highlighted the importance of understanding each client’s challenges and determining the most advantageous use of 3D printing to overcome them. This vision is reaffirmed by the 3DaaS® model at LABi3D, which combines cutting-edge technology with strategy to meet the needs of Petrobras.
In 2021, we also published an article on advancements in 3D printing at Petrobras, highlighting the company’s challenges and achievements in adopting this technology. Challenges included the need to expand and diversify 3D printing materials to meet the stringent regulations of the oil and gas industry, particularly in the use of metals to produce parts with complex geometries. Achievements included the development of methodologies for metal 3D printing, such as powder bed fusion (PBF) and directed energy deposition (DED) using lasers, in partnerships with institutions like Carl Zeiss and SENAI. LABi3D represents a milestone in this journey, combining innovation and strategy to strengthen Petrobras’ presence in Industry 4.0.
The Research & Development Tax Credit
The now permanent Research and Development (R&D) Tax Credit is available for companies developing new or improved products, processes and/or software.
3D printing can help boost a company’s R&D Tax Credits. Wages for technical employees creating, testing and revising 3D printed prototypes can be included as a percentage of eligible time spent for the R&D Tax Credit. Similarly, when used as a method of improving a process, time spent integrating 3D printing hardware and software counts as an eligible activity. Lastly, when used for modeling and preproduction, the costs of filaments consumed during the development process may also be recovered.
Whether it is used for creating and testing prototypes or for final production, 3D printing is a great indicator that R&D Credit-eligible activities are taking place. Companies implementing this technology at any point should consider taking advantage of R&D Tax Credits.
Conclusion
By consolidating its commitment to additive manufacturing, Petrobras is not only modernizing its processes but also establishing new standards of efficiency and sustainability for the energy industry. The partnership with 3DCRIAR and other institutions highlights the value of collaboration in such a competitive sector, demonstrating how investment in emerging technologies can generate a significant impact on a global scale. The success of LABi3D reflects not only the technological advances achieved but also the transformative potential of additive manufacturing to redesign the future of the oil and gas industry. With the 3DaaS® model and the LABi3D infrastructure, Petrobras takes a step forward in the race for Industry 4.0, establishing an example of how the convergence between technology, expertise, and innovation can transform not only a company’s operations but also benefit the entire production chain.
