# US 2019/0169965 A1 · Additive Manufacture of Wellbore Lining > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0169965 A1 - Document ID: US20190169965A1 - Status: Published application - Kind: A1 - Application number: 16/206,190 - Filed: 2018-11-30 - Published: 2019-06-06 - Earliest claimed: 2017-12-05 - Assignees: Saudi Arabian Oil Company - Applicants: Saudi Arabian Oil Company - Inventors: Peter J. Boul; Carl J. Thaemlitz - Web page: https://patentgrep.com/patent/US20190169965A1 ## CPC - E21B 33/14: for cementing casings into boreholes - B22F 10/00: Additive manufacturing of workpieces or articles from metallic powder (apparatus or devices therefor B22F12/00) - B22F 10/85: for controlling or regulating additive manufacturing processes - B22F 12/00: Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices - B22F 12/82: Combination of additive manufacturing apparatus or devices with other processing apparatus or devices - B28B 1/001: {Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00)} - B28B 13/022: {Feeding several successive layers, optionally of different materials} - B28B 13/0275: {Feeding a slurry or a ceramic slip} - B28B 17/0081: {Process control} - B29C 64/00: Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering - B29C 64/10: Processes of additive manufacturing - B29C 64/112: using individual droplets, e.g. from jetting heads - B29C 64/176: Sequentially - B29C 64/182: in parallel batches - B29C 64/20: Apparatus for additive manufacturing; Details thereof or accessories therefor - B29C 64/205: Means for applying layers - B29C 64/227: Driving means - B29C 64/241: for rotary motion - B29C 64/245: Platforms or substrates (support structures intended to be sacrificed after manufacture B29C64/40) - B29C 64/25: Housings, e.g. machine housings - B29C 64/255: Enclosures for the building material, e.g. powder containers - B29C 64/30: Auxiliary operations or equipment - B29C 64/307: Handling of material to be used in additive manufacturing - B29C 64/386: Data acquisition or data processing for additive manufacturing - B29C 64/393: for controlling or regulating additive manufacturing processes - B29C 64/40: Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof - B33Y 40/00: Auxiliary operations or equipment, e.g. for material handling - B33Y 40/10: Pre-treatment - B33Y 40/20: Post-treatment, e.g. curing, coating or polishing - B33Y 50/00: Data acquisition or data processing for additive manufacturing - B33Y 70/00: Materials specially adapted for additive manufacturing - B33Y 70/10: Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials - B33Y 99/00: Subject matter not provided for in other groups of this subclass - E21B 41/0078: {Nozzles used in boreholes (drilling by liquid or gas jets E21B7/18; drill bits with nozzles E21B10/60; perforators using direct fluid action E21B43/114; obtaining a slurry of minerals using nozzles E21B43/29)} - E21B 43/10: Setting of casings, screens, liners {or the like} in wells - B33Y 10/00: Processes of additive manufacturing - B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor - B33Y 50/02: for controlling or regulating additive manufacturing processes - B33Y 80/00: Products made by additive manufacturing - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING ## Abstract Provided are systems and methods for forming a casing liner in a wellbore of a hydrocarbon well. The forming including disposing a casing liner print head in an annular region located between a casing pipe disposed in a wellbore of a hydrocarbon well and a wall of the wellbore, conducting a downhole lining operation including operating the casing liner print head to eject casing liner integrated structure material into the annular region to form, in the annular region, a casing liner integrated structure including contiguous voids formed in the casing liner integrated structure material, and depositing a cementitious material into the contiguous voids formed in the casing liner material to form, in the annular region, a casing liner including the casing liner integrated structure material and the cementitious material. ## Claims ### Claim 1 A method of forming a casing liner in a wellbore of a hydrocarbon well, the method comprising: disposing a casing liner print head in an annular region located between a casing pipe disposed in a wellbore of a hydrocarbon well and a wall of the wellbore; conducting a downhole lining operation comprising operating the casing liner print head to eject casing liner integrated structure material into the annular region to form, in the annular region, a casing liner integrated structure comprising contiguous voids formed in the casing liner integrated structure material; and depositing a cementitious material into the contiguous voids formed in the casing liner material to form, in the annular region, a casing liner comprising the casing liner integrated structure material and the cementitious material. ### Claim 2 (depends on 1) The method of claim 1, wherein the downhole lining operation comprises advancing the casing liner print head along a length of the wellbore and ejecting the casing liner integrated structure material along a length of the annular region to form the casing liner integrated structure along the length of the annular region. ### Claim 3 (depends on 1) The system of claim 1, wherein the casing liner integrated structure material comprises a polymer. ### Claim 4 (depends on 1) The method of claim 1, wherein the casing liner integrated structure material has a Young's Modulus that is less than a Young's Modulus of the cementitious material. ### Claim 5 (depends on 1) The method of claim 1, wherein the casing liner integrated structure comprises longitudinally oriented structural elements and corresponding longitudinally oriented void regions. ### Claim 6 (depends on 5) The method of claim 5, wherein the casing liner integrated structure comprises a honeycomb shaped integrated structure having longitudinally oriented hexagonal structural elements and corresponding longitudinally oriented hexagonal void regions. ### Claim 7 (depends on 1) The method of claim 1, wherein the casing liner integrated structure comprises a radially oriented hexagonal structural elements and corresponding radially oriented void regions. ### Claim 8 (depends on 7) The method of claim 7, wherein the casing liner integrated structure comprises a honeycomb shaped integrated structure having radially oriented hexagonal structural elements and corresponding radially oriented hexagonal void regions. ### Claim 9 A wellbore casing liner printing system comprising: a casing liner print head configured to be disposed in an annular region located between a casing pipe disposed in a wellbore of a hydrocarbon well and a wall of the wellbore, the casing liner print head configured to eject casing liner integrated structure material into the annular region to form, in the annular region, a casing liner integrated structure comprising contiguous voids formed in the casing liner integrated structure material; and a cementing system configured to deposit cementitious material into the contiguous voids formed in the casing liner material to form, in the annular region, a casing liner comprising the casing liner integrated structure material and the cementitious material. ### Claim 10 (depends on 9) The system of claim 9, wherein the casing liner print head is configured to be advanced along a length of the wellbore and to eject the casing liner integrated structure material along a length of the annular region to form the casing liner integrated structure along the length of the annular region. ### Claim 11 (depends on 9) The system of claim 9, wherein the casing liner integrated structure material comprises a polymer. ### Claim 12 (depends on 9) The system of claim 9, wherein the casing liner integrated structure material has a Young's Modulus that is less than a Young's Modulus of the cementitious material. ### Claim 13 (depends on 9) The system of claim 9, wherein the casing liner integrated structure comprises longitudinally oriented structural elements and corresponding longitudinally oriented void regions. ### Claim 14 (depends on 13) The system of claim 13, wherein the casing liner integrated structure comprises a honeycomb shaped integrated structure having longitudinally oriented hexagonal structural elements and corresponding longitudinally oriented hexagonal void regions. ### Claim 15 (depends on 9) The system of claim 9, wherein the casing liner integrated structure comprises an radially oriented hexagonal structural elements and corresponding radially oriented void regions. ### Claim 16 (depends on 15) The system of claim 15, wherein the casing liner integrated structure comprises a honeycomb shaped integrated structure having radially oriented hexagonal structural elements and corresponding radially oriented hexagonal void regions. ### Claim 17 A method of forming a casing liner in a wellbore of a hydrocarbon well, the method comprising: disposing a casing liner print head in an annular region located between a casing pipe disposed in a wellbore of a hydrocarbon well and a wall of the wellbore; conducting a downhole lining operation comprising operating the casing liner print head to eject casing liner integrated structure material into the annular region to form, in the annular region, a casing liner integrated structure comprising contiguous voids formed in the casing liner integrated structure material; and depositing casing cement into the contiguous voids formed in the casing liner material to form, in the annular region, a casing liner comprising the casing liner integrated structure material and the casing cement. ### Claim 18 (depends on 17) The method of claim 17, wherein the downhole lining operation comprises advancing the casing liner print head along a length of the wellbore and ejecting the casing liner integrated structure material along a length of the annular region to form the casing liner integrated structure along the length of the annular region.