3D printing has fully permeated the energy sector and is no longer just about curious prototypes or home-printed "toys." We're talking about a technology that is changing the way we design turbines, solar panels, oil and gas equipment, green hydrogen solutions, and even advanced CO2 capture systems. All of this with a clear objective: to reduce costs, increase efficiency, and move towards a more sustainable energy model.
With the pressure of climate change, dwindling fossil fuels, and increasingly stringent regulations, energy companies are seeking any competitive advantage. Additive manufacturing offers something that traditional methods cannot match: complete design freedom, on-demand manufacturing, and far more flexible supply chains . Let's take a clear and direct look at how this technology is already being used and where it's all headed.
What does 3D printing really bring to the energy sector?
When we talk about 3D printing, or additive manufacturing, we're referring to a set of processes that build parts by adding material layer by layer, based on a CAD model. Unlike traditional machining or molding, which start with a block or a mold, here only the necessary material is deposited with millimeter precision.
The energy sector is critical because it underpins much of economic activity and daily life . Industry, households, transportation, and, to a large extent, social stability depend on its reliability. At the same time, it is one of the largest emitters of greenhouse gases, so the pressure to decarbonize is enormous. In this context, additive manufacturing is positioning itself as a key lever for accelerating the transition to renewables without compromising security of supply.
The great advantage of 3D printing is that it allows for the creation of custom components with geometries previously impossible to manufacture , reducing the development time for new solutions and enabling the remote production of spare parts in record time. All of this helps to reduce supply chain risk, minimize downtime, and cut operating and maintenance costs.
Rapid prototypes, production parts and spare parts on demand
In the development of energy equipment, prototypes are commonplace: conceptual mock-ups, functional scale models, iterative versions of the same design . Previously, handmade mock-ups or manufactured molds (often from external suppliers) were used, with lead times of weeks or months and very high costs.
With 3D printing, that development cycle is radically compressed . Engineers can design a part, print it in hours or a few days, validate it, correct it, and repeat. This translates into more iterations in less time , better early detection of design errors, and a faster time to market—something especially valuable in emerging technologies such as hydrogen, offshore wind, or new generations of solar panels.
An illustrative example is the Stones project, the ultra-deepwater oil and gas field in the Gulf of Mexico . Operating at a depth of nearly 2.900 meters, it requires complex subsea infrastructure to transport hydrocarbons to a floating production, storage, and offloading (FPSO) vessel. 3D printing enabled the creation of physical prototypes of the system connecting the FPSO to the seabed pipelines , facilitating the demonstration of the concept to US regulatory authorities, who were required to authorize this type of solution for the first time in the region.
But it's no longer just about prototypes. In the energy sector , high-value, highly complex end-use parts are beginning to be manufactured : nozzles and components for gas turbines, impellers, pistons, pumps, rotors, control valve elements, flow meters, heat exchangers, pressure gauges, and more. In these cases, metal additive manufacturing (SLM, DMLS, etc.) takes center stage , because we're talking about high-pressure environments, extreme temperatures, and very strict safety requirements.
To date, only a fraction of 3D-printed components are certified for critical use in power generation, nuclear power, or large oil and gas installations. The reason is obvious: a failure could have a catastrophic impact on people, wildlife, and the environment. Companies and regulatory bodies are very cautious about replacing traditional methods with new ones . However, as specific standards are established and success stories accumulate, this barrier is gradually being lowered.
In operations and maintenance, 3D printing is proving to be a cost-saving measure. In the oil and gas sector, it is estimated that 1% annual downtime can cost millions , and on offshore platforms, we're talking about almost a month of unplanned downtime per year, with losses in the tens of millions. Approximately half of that downtime is associated with hardware breakdowns or failures.
Traditionally, the solution was to maintain large spare parts warehouses, with tied-up capital and considerable logistical costs. Additive manufacturing allows for a different approach: reliable parts printed on demand, close to the asset or even on-site , without the need for huge stockpiles, minimum order quantities, and without redesigning obsolete components from scratch.
With 3D scanning and reverse engineering, it's possible to digitize and recreate discontinued components , redesign them for additive manufacturing , and produce them when needed. Often, this results in lighter parts with optimized internal channels for cooling or flow, and superior performance compared to the original , reducing costs in time, materials, and labor.
Green Hydrogen and Direct Ink Writing: From Mining Waste to Electrode
One of the most interesting lines of research is the use of 3D printing to produce green hydrogen and ammonia . In Chile, at the Federico Santa MarÃa Technical University (USM), a team led by Professor Claudio Aguilar is working with Direct Ink Writing (DIW) technology , integrated into a PowerDIW system developed by CIM UPC.
This technology is based on the extrusion of highly viscous pastes loaded with solid particles , which are deposited layer by layer to create functional 3D objects. The major advantage is that it allows the printing of materials that could not be processed using conventional methods , including ceramics, metals, biomaterials, and polymers with high particle loads.
In this case, the USM group uses waste from large-scale mining, such as copper slag, to manufacture electrodes capable of producing green hydrogen and ammonia. From this waste, they recover elements like iron, silicon, and molybdenum and transform them into high-performance materials for electrocatalysis . According to Aguilar, the resulting electrodes are not only much cheaper but also more efficient than those that use precious metals like platinum or ruthenium , which are expensive and scarce.
The PowerDIW printer has become a central tool in the lab because it allows for precise adjustment of the paste formulations , varying the particle load according to the project's needs. This opens the door to experimenting with new advanced materials and processes, not only for energy but also for sectors such as healthcare (prototypes of prostheses and biomaterials), mining, and the manufacture of small-scale turbine blades.
Among the most valued features of the PowerDIW system are its high extrusion force, multi-material capability, and machine robustness , all at a relatively low cost. The group plans to acquire another unit to further explore multi-material combinations, such as high-entropy alloys combined with copper for high-performance electrical contactors.
DIW technology itself presents itself as a highly versatile solution for healthcare and biotechnology, electronics and energy, manufacturing, pharmaceuticals, and chemicals . From printing tissues and medical devices to sensors, fuel cells, ceramic components, and microreactors , the range of applications continues to expand thanks to its modular design and the ability to customize the printhead and system functionalities.
Renewable energy transition and new designs for solar, wind and storage
The shift towards a renewable energy model requires reducing costs, increasing efficiency, and shortening deployment times . 3D printing fits perfectly here, as it allows for both the development of complex prototypes at low cost and the manufacture of certain optimized final components.
Two major avenues are being explored in solar energy. One involves the application of 3D-printed semiconductor inks on ultrathin wafers . Formulations based, for example, on mixtures of boron and polysilicon are used, deposited with high precision onto cells only about 200 microns thick. The result is a larger effective contact surface and, therefore, increased conversion efficiency , with improvements of around 20%, and at lower costs.
On the other hand, some companies are investing in volumetric 3D printing processes to manufacture advanced solar panels . These techniques allow for the curing of an entire volume of material at once, without layering, which greatly accelerates manufacturing and reduces the unit cost . The goal is to make solar electricity more accessible globally.
Another key area of ​​research is next-generation solar cells, such as perovskite cells . By 3D printing scaffold-like structures with optimized geometry, it's possible to create absorbent layers with improved optical and electrical properties , reduce charge carrier recombination, and enhance light management. Work is underway on thin films with complex 3D structures that overcome the limitations of traditional silicon wafers, both in terms of cost and environmental impact.
Beyond the cells themselves, additive manufacturing also helps improve electrical connections, interconnectors, substrates, and structural elements of the modules, precisely adjusting internal geometries, porosity, and surface roughness. All of this contributes to greater performance and a longer lifespan for the panels.
In wind energy, 3D printing is present from the prototyping phase of blades and components to the manufacture of large-format molds and, in some projects, even in the production of complete structural sections. Techniques such as FDM and SLS are commonly used for prototypes and small to medium-sized parts , while DMLS or DLMS are employed for highly precise metal components in nacelles, transmission systems, brakes, or bearings.
Companies like Siemens Gamesa and Vestas have already integrated metal 3D printing to manufacture and optimize certain components of their turbines . In parallel, large-format printers , such as the one being developed by the University of Maine, are being created to manufacture full-size molds for turbine blades using cheaper and potentially recyclable biopolymers.
The startup Orbital Composites, for example, is working with 3D printing robots to produce wind turbine blades and structures on-site , even considering manufacturing them offshore aboard ships. Their goal is to overcome current logistical limitations (in countries like the United States, transportation limits blade length to around 53-62 meters) and enable turbines with blades longer than 100 meters to be produced directly where they will operate.
Furthermore, waste from old turbine blades is being transformed into new printable materials, closing the loop and addressing one of the industry's major challenges: the recycling of fiberglass-reinforced composites. The use of 3D printing allows for the creation of lightweight and complex structures that reduce the turbine's overall weight and improve its aerodynamic performance.
In energy storage, additive manufacturing enables the development of batteries and supercapacitors with unconventional geometries . Instead of being limited to cylindrical or prismatic shapes, custom designs are being explored that integrate better into portable devices, vehicles, or industrial equipment , taking advantage of 3D internal structures that increase the active surface area and improve energy or power density.
3D printing is also being used to produce fuel cells and electrolyzers , both proton exchange membrane (PEM) and solid oxide (SOC) types. The ability to deposit thin layers of electrolytes, functional electrodes, and catalysts with graded compositions allows for optimization of cell performance. Advances in stereolithography and DLP for ionic-conducting ceramics are paving the way for more complex and compact designs, bringing the next generation of high-efficiency devices closer to reality.
3D printing in fossil fuels and carbon capture
Although the priority is to move towards renewables, fossil fuels still play a significant role, and 3D printing is also helping to reduce their environmental impact and improve efficiency . In drilling equipment, for example, additive manufacturing allows for the design of lighter, stronger components adapted to extreme conditions , which reduces energy consumption and improves safety.
The ability to manufacture custom parts with complex internal channels facilitates cooling, lubrication, and structural behavior of critical tools, minimizing the risk of catastrophic failures. Furthermore, many advanced operations are opting for recyclable or more sustainable materials , reducing the overall carbon footprint of drilling activity.
In carbon capture (CC), one of the main challenges is reducing the energy consumption of the process . Systems based on liquid solvents, although mature, suffer from corrosion problems, low CO2 capacity, and the need for intense cooling to manage the exothermic reaction between the gas and the absorbent.
Additive manufacturing offers the possibility of designing heat exchangers and reactors with extremely complex internal geometries , impossible to achieve with conventional methods. This allows for optimized interstage cooling, improved heat transfer, and increased capture efficiency while maintaining the absorber within an optimal temperature range.
By integrating thermal and process functions into a single unit, the number of components is reduced, losses are minimized, and the overall efficiency of capture systems is improved, making the decarbonization of large industrial facilities cheaper.
Technical, regulatory and scaling challenges in additive manufacturing
Of course, it's not all advantages. One of the main obstacles remains the availability and behavior of materials . Many 3D printing processes work primarily with polymers or resins, while the energy sector typically requires high-strength metals, advanced alloys, structural ceramics, or materials with very specific electrical and thermal properties.
In applications such as solar cells, fuel cells, and nuclear components, highly precise properties of conductivity, thermal stability, mechanical strength, and durability are required . Although metal and ceramic solutions already exist, many combinations still need to be validated, and the certification of new materials and printing parameters is neither quick nor inexpensive.
Another problem is scaling up production . For short runs or highly complex parts, 3D printing is very competitive, but when it comes to mass production of simple components, cost and speed don't always match traditional manufacturing . Furthermore, high-volume machines are often limited to certain sizes and materials, which complicates their use in large-scale energy projects.
The quality of the parts themselves can vary if process parameters and environmental conditions are not rigorously controlled . Without clear standardization, it is difficult to guarantee that a part printed in one plant meets the same specifications as one manufactured on another continent, using a different machine or even a different software version.
Added to this are regulatory and environmental concerns . The intensive use of certain plastics, the emission of ultrafine particles in some processes, and the electricity consumption of certain advanced printers can clash with sustainability goals if not managed properly. This is why there is growing interest in bio-based, biodegradable materials and processes with high reuse of powder or raw materials.
The issue of intellectual property and cybersecurity is also significant. When the value of the physical object is transferred to the design file, new risks emerge: unauthorized copies, manipulated designs, or prints made without adhering to the original specifications. In critical sectors such as energy, a pirated or poorly printed component can become a considerable security and legal liability problem.
Eco-friendly materials and carbon footprint reduction in 3D printing
Alongside all these applications, so-called "green" 3D printing is gaining traction , focusing on materials and processes with a lower environmental impact. A good example is bio-based nylon PA11 , derived from castor oil. This crop does not compete with the food chain, utilizes marginal land, and requires less water , thus reducing its environmental footprint compared to petroleum-based thermoplastics.
In processes such as HP Multi Jet Fusion, PA11 can be reused very efficiently , minimizing unfused powder waste. In addition to its sustainable profile, it offers good mechanical strength, flexibility, and high chemical resistance , making it attractive for housings, ducts, and components subjected to moderate stress within energy equipment.
Another noteworthy material is ECOtech, a biodegradable polymer certified according to DIN EN ISO 14855. It combines mechanical properties comparable to those of certain conventional thermoplastics with the ability to degrade in a controlled manner under suitable conditions, helping to reduce plastic waste in the long term.
Significant improvements have also been achieved in materials such as PA12, glass-filled PA12, PP, white PA12, and TPU . For example, some grades of PA12 have achieved a nearly 50% reduction in their carbon footprint thanks to the use of renewable energy in their production and higher powder reuse rates.
In fact, increasing powder reuse from 50% to 80% in certain processes can reduce a part's carbon footprint by up to 70%. In the case of PP, reuse rates are close to 90% , further reducing the impact associated with the material and the energy consumed during the printing phase.
3D printing also allows for radical design optimization : lighter parts, consolidation of multiple components into one, and strategic internal geometries. All of this translates into less material, less weight, and less energy required for manufacturing, transport, and operation . There are real-world examples where redesigning a part using additive manufacturing has resulted in reductions of 38% in CO2 emissions, 95% in costs, and 90% in weight compared to the traditional version.
If local or even on-site production is added to this , logistical journeys and emissions associated with transport are reduced, something especially valuable in the deployment of renewable infrastructure in remote or hard-to-reach areas.
Innovation, collaboration and the role of governments and industry
The evolution of 3D printing in energy goes hand in hand with advances in materials, printing techniques, and design software . The incorporation of advanced metals, high-performance ceramics, and multi-material composites expands the range of possible applications in turbomachinery, reactors, nuclear components, storage devices, and offshore structures.
Multi-material printing, meanwhile, allows for the combination of different areas with distinct properties in a single piece : conductive and insulating, rigid and flexible, corrosion-resistant on one side and thermally optimized on the other. This capability is very interesting for integrated sensors, smart structural components, and "connected" energy equipment.
By combining additive manufacturing with other emerging technologies such as artificial intelligence, augmented/virtual reality, collaborative robotics, and the Internet of Things , powerful workflows are unlocked. AI algorithms can optimize designs and printing parameters ; AR and VR facilitate the inspection and validation of models; robotics enables the automation of large-scale printing cells ; and IoT helps monitor the performance of installed components, closing the design loop.
Collaborations between universities, technology centers, industrial companies, and printing equipment manufacturers are proving crucial. Projects funded by public bodies, such as ministries of economy or energy efficiency agencies, and by national laboratories like ORNL or the DOE in the United States, are accelerating the development of large-format molds, printed concrete structures, anchors for offshore wind turbines, and new tools for rotor blades.
In Europe, funding is also being allocated to initiatives that print giant sand molds for nacelle components , shortening manufacturing times from weeks to just a few days and reducing the carbon footprint by producing closer to the installation site. Projects like ACC and Winddruck are exploring how to make large-scale wind turbine blade manufacturing cheaper and more sustainable , with a view to using renewable and recyclable materials.
Governments, for their part, can play a decisive role through R&D programs, tax incentives, and clear regulatory frameworks that facilitate the certification of printed components for critical use. Establishing internationally aligned quality standards and norms is essential for companies to feel confident adopting these technologies in key energy infrastructure.
The rise of 3D printing in energy is not a passing fad: it responds to very specific needs for efficiency, sustainability, speed, and supply chain resilience . From entire wind turbines designed and printed in a single piece for wind tunnel testing to hybrid wind turbines with integrated photovoltaic panels developed in Spain, and including on-demand spare parts supply networks for offshore platforms, real-world examples are multiplying and show that the leap forward is already underway.
In this context, the companies best positioned in the coming years will be those that successfully integrate additive manufacturing into their energy strategy : carefully selecting processes and materials, collaborating with technology partners, investing in advanced design, and committing to increasingly sustainable materials and methods. 3D printing won't replace all traditional manufacturing at once, but it is becoming a key piece of the new global energy puzzle.
