Obsolete components
Recreate discontinued parts from existing samples or technical data, without recreating the original casting patterns or production tooling.
Replacement parts.For Oil & Gas.
Keep serviceable equipment operating when spare parts become a supply bottleneck. We help oil and gas operators and maintenance providers recreate unavailable components, assess replacements for obsolete designs, and establish repeat local supply, reducing dependence on overseas sourcing and large minimum orders.
The OEM has moved on.The equipment has not.
A single unavailable component can delay maintenance or lead to replacing an otherwise serviceable assembly. We combine reverse engineering and additive manufacturing to assess alternative supply options and produce components around your equipment requirements.
Long-lead spares
Explore local production for spares that are difficult to source, with quantities aligned to maintenance needs rather than large production runs.
Complex internal geometry
Produce intricate internal passages and integrated features, creating opportunities to simplify assemblies and develop designs beyond conventional manufacturing constraints.
A labyrinth cage,rebuilt for metal 3D printing.
Working with oil and gas consultant 3D Energy and technology partner Eplus3D, we reconstructed an existing valve cage and produced it by metal additive manufacturing.
- Under 3 weeks
- Design to printed part, including specimen testing
- Industry
- Oil & Gas
- Application
- Labyrinth cage, valve component
- Approach
- High-resolution 3D scanning, design review and metal AM with specimen testing
No drawings left?Scan, model, verify.
Most legacy parts arrive without usable data. We capture the original, rebuild it as engineering CAD and prove the new geometry against the scan before metal is committed.
- Capture
- Metrology-grade scanning up to 0.020 mm with SIMSCAN, or 0.025 mm with HandySCAN 3D BLACK and NimbleTrack, in our facility or on site.
- Rebuild
- Clean CAD with critical interfaces, bores and sealing faces modelled to your requirements.
- Verify
- Colour deviation maps compare the new model and the printed part with the original.
Three different production processes, standing on one floor.
Large-format FDM, production FDM, polymer SLS and metal powder bed fusion. All four are owned and run in Jebel Ali.
More about the Stratasys F900
More about the Stratasys Fortus 450mc
More about the EOS P 396
More about the Eplus3D EP-M300
Large format polymer manufacturing for functional end parts, production tooling, and prototypes. Produce larger parts in one piece, reducing the need for splitting and assembly.
Available materials include ULTEM 9085, Nylon 12CF, ASA and more.
More about the Stratasys F900* Build envelopes are given as X × Y × Z.
Materials libraryTemperature, pressure, media.Then the material.
We start from the service conditions and the current material specification. The alloy or polymer, the build route and the testing are planned as one scope.
| Service condition | What we need to know | Why it matters |
|---|---|---|
| Temperature | Continuous and peak temperature, thermal cycling | Sets the alloy family or rules out polymers |
| Pressure and load | Operating pressure, mechanical and cyclic loads | Drives wall thickness, build orientation and testing |
| Process media | Hydrocarbons, water, H₂S, chemicals and cleaning agents | Defines corrosion and chemical resistance needs |
| Current specification | Original material, grade and any standards cited | Gives the baseline the replacement is measured against |
| Location | Hazardous area, offshore or indoor service | Affects qualification, documentation and approval steps |
Finished to fit.Checked before it ships.
Sealing faces, bores and threads decide whether a part goes back into service. We plan them into the build, not after it.
- Machining allowances
- Extra stock planned on critical faces and bores so they can be finished to drawing tolerance.
- Post-build operations
- Support removal, surface preparation and any heat treatment defined with the alloy and build plan.
- Inserts and assembly
- Threaded inserts, fasteners and sub-assemblies fitted and checked for polymer parts and tooling.
- Dimensional inspection
- Scan-based comparison against CAD, with the records your acceptance criteria require.
Operating conditions.Clear acceptance criteria.
Tell us what the part must do and how it will be accepted. Pressure-containing, safety-critical or hazardous-area parts need their qualification and approval route defined at the start.
Testing, documentation and approval scope are confirmed per order.
- Part and source data
- Part number, CAD, drawings or photographs, and a physical sample where available.
- Operating conditions
- Temperature, pressure, process media, loading, exposure and intended function.
- Material and interfaces
- Current material specification, mating features and critical dimensions.
- Quantity and schedule
- Required quantity, repeat demand, shutdown dates and your requested delivery.
- Acceptance and records
- Inspection criteria, specimen or material testing, finishing and documentation.
Questions frommaintenance and procurement.
Anything else? See all FAQs
Can you manufacture replacement internals for legacy valves?
We can assess valve trim and other internal components from drawings or existing samples. The review considers flow geometry, mating interfaces, operating conditions and the finishing needed before assembly and testing.
Can additive manufacturing reproduce complex flow-control geometries?
Metal printing offers a production route for intricate passages and cage geometries that can be difficult to manufacture conventionally. We work from your design and coordinate manufacturing requirements with your valve specialist or engineering consultant.
Can you support pump refurbishment when individual components are unavailable?
We assess components such as impellers for reverse engineering and manufacture. Hydraulic geometry, shaft interfaces, material requirements and subsequent machining, balancing and testing are defined with the party responsible for the refurbishment.
Can polymer prototypes help before committing to a metal replacement?
Yes. A polymer model can help check assembly clearances, installation access and fit during valve or pump overhaul. This provides an opportunity to resolve dimensional issues before metal production.
Can you manufacture parts for corrosive, high-temperature or sour-service conditions?
These enquiries require the specified material grade, process conditions and acceptance criteria. We review whether the proposed manufacturing route can meet those requirements before confirming scope; alloy availability alone does not establish service suitability.
Bring us the part.
Send a drawing, a CAD file, or photographs and the old part. Tell us what it does, how many you need and when.