Aker Solutions establishes 3D printing center for offshore maintenance

Aker Solutions has opened a new 3D printing center in Trondheim to investigate the use of additive manufacturing in the offshore industry. The aim is to use new technologies to cut costs, simplify processes and reduce emissions. The center was launched as part of a seven-month pilot project for Equinor, which includes the maintenance and modification of equipment on the Troll and Heidrun fields.

The project includes the integration of new workflows, software solutions and a network of 3D printing facilities. From problem analysis to final offshore installation, Aker Solutions’ engineering expertise plays a central role. The pilot could be expanded in the long term and open up new possibilities for the management of offshore installations.

“At Aker Solutions, continuous improvement is at the core of everything we do. That means always looking for ways to enhance efficiency and streamline operations. 3D printing has the potential to revolutionize offshore maintenance, making processes quicker, more cost-effective, and more sustainable. Simply put, if a process can be simplified, we must simplify it,” said Paal Eikeseth, Executive Vice President and Head of Aker Solutions’ Life Cycle segment.

Additive manufacturing offers several advantages for the offshore industry. It enables the production of spare parts on demand, which reduces transportation and material costs. It also reduces waste and energy consumption, as components are manufactured in a targeted manner instead of using conventional, often material-intensive processes. In maintenance, 3D printing allows out-of-stock spare parts to be reproduced, minimizing downtime and avoiding costly complete replacements.

“Working with AM means designing smaller parts of larger equipment, which presents unique challenges for our engineers. We will establish new repair methods, and our ambition is to revolutionize how spare parts are managed under the frame agreement. Exploring and adopting new technologies is key to our digital strategy, and this is a perfect example of how we integrate innovation into our daily work,” said Eikeseth.

The center serves as an innovation platform where engineers test additive manufacturing technologies and develop new repair methods. One focus is on the design of individual components for complex systems, which poses particular challenges for the design and choice of materials. Aker Solutions plans to use new processes to make spare parts management more efficient and establish additive manufacturing as an integral part of its digital strategy.

Aker Solutions began using 3D printing as part of Equinor’s Johan Castberg project. More than 7,000 components were printed, 60% of which were made of plastic and 40% of steel. This project led to the development of the “Castberg model”, which formed the basis for another 3D printing laboratory at the Stord site, which was put into operation in October 2024. Aker Solutions now operates more than 50 3D printers at various locations and uses the technology as an integral part of its manufacturing processes.

“We must credit Equinor’s ambitions for 3D printing as a driving force behind our journey. Thank you for including us in the learning curve, sharing knowledge, and collaborating to build our digital inventory,” said Aker Solutions’ CEO Kjetel Digre during the opening of ADDMO in Trondheim.