The energy and oil & gas industries face unique manufacturing challenges. Components often operate in extreme conditions, are produced in low volumes yet must deliver high reliability, and can be difficult or expensive to source through traditional supply chains. At the same time, downtime due to worn or failed parts can significantly impact operational costs and asset availability.
AltForm supports OEMs, plant operators, and service providers in this sector with Powder Bed Fusion (PBF), Direct Energy Deposition (DED), advanced laser processes, automation, and software platforms designed to improve efficiency, reduce lead time, and enable new ways of managing parts, repair, and production.
Our solutions are used for prototyping, repair, remanufacturing, and qualified production workflows that meet the demanding requirements of energy production, power generation, and oil & gas infrastructure.
Remanufacturing high-value components with automated workflows
One of the most impactful applications of metal additive manufacturing in the energy and oil & gas sector is remanufacturing wear-prone, high-value components. Instead of replacing entire assemblies, plant operators can restore components to serviceable condition, using DED technologies to rebuild surfaces or worn sections with high precision.
AltForm can design and deliver fully automated remanufacturing lines that integrate additive, subtractive, and inspection technologies. These end-to-end workflows can include:
- robotic handling and part positioning
- automated material delivery and powder management
- integrated quality monitoring and inspection
- unified software control for scheduling, process data, and reporting
This approach enables on-site or near-site remanufacturing, reducing the need for long supply chain loops, minimizing production downtime, and extending the service life of critical equipment.
Extending life and performance with advanced coating
In the oil & gas sector, laser-based coating is a key tool for improving the performance and durability of components exposed to corrosive environments, abrasion, and thermal cycling. Coating hard surfaces with wear-resistant alloys reduces maintenance frequency and extends the service life of parts such as:
- drill bits and drilling sub-assemblies
- valve seats and seals
- pump components
- flow control elements
AltForm’s rapid coating solutions are engineered for industrial use, enabling high throughput, consistent layer quality, and integration into automated lines. The result is parts that can withstand harsh offshore, subsea, and refinery environments with improved corrosion resistance and mechanical performance.
Powder Bed Fusion for complex, high-performance parts
Powder Bed Fusion plays an essential role in energy and oil & gas applications where complexity, precision, and material properties matter. With platforms like Print 300 and Print 400, manufacturers can produce components with lattice structures, internal cooling channels, and optimized strength-to-weight ratios that would be difficult or impossible with conventional manufacturing.
Typical applications include:
- turbine components for power generation
- casings and housing for high-pressure systems
- parts for subsea and offshore production equipment
- heat exchangers and cooling system elements
PBF enables rapid iteration from prototype to qualified production and supports advanced alloys suitable for extreme environments.
Reducing downtime and strengthening supply chain resilience
Energy and oil & gas operations are often distributed, remote, or operate continuously for long periods. Delays in spare parts delivery can translate into significant losses. Additive manufacturing helps reduce this risk by enabling:
- on-demand production of spare parts
- reduced reliance on large inventories
- production nearer to point of use
- faster turnaround times for replacement parts
By pairing advanced manufacturing with digital workflows and automated production lines, manufacturers can improve operational readiness and reduce total lifecycle cost.
Materials engineered for extreme conditions
AltForm solutions support a wide range of materials critical for energy and oil & gas environments, including high-temperature alloys, corrosion-resistant steels, nickel-based superalloys, and specialized metal mixes. These materials are processed under precise control to ensure mechanical performance, fatigue resistance, and reliability in challenging applications.
Process control, monitoring, and automation ensure stable, repeatable results at an industrial scale and support qualification for demanding environments.
Our solutions for the energy, oil & gas industry
ZENIT Cell
Print 300 Series
Print 400 Series
