Sustainable Manufacturing of Oilfield Spare Parts Using 3D Printing: Mechanical Reliability, Economic Feasibility, and HSE Risk Mitigation in Libya

This study evaluates the feasibility of using 3D printing technology to manufacture critical mechanical spare parts in Libyan oilfields, focusing on mechanical performance, economic efficiency, and HSE compliance. Using industrial-grade 3D printers (Markforged X7), valve components, gear housings, and pipe connectors were fabricated from PLA, ABS, and carbon-fiber-reinforced nylon (CFRN). Mechanical testing (ASTM D638/D695) and statistical analysis (ANOVA, Weibull modeling) revealed that CFRN achieved 70% of OEM steel tensile strength (72.3 ± 4.1 MPa vs. 103.5 MPa, p< 0.001) with 50% weight reduction, while reducing lead time by 76.7% (30 → 7 days) and cutting costs by 50% per part. However, ABS emitted 85 ± 9.7 µg/m³ PM₂.₅, exceeding OSHA limits (*p=0.013*), necessitating HEPA filtration and enclosed printing systems. The results demonstrate that CFRN is viable for non-critical parts, yielding $2.1M/year savings for mid-sized oilfields, whereas ABS requires stringent HSE controls.Keywords: Additive manufacturing, oilfield spare parts, mechanical reliability, economic feasibility, HSE compliance, carbon-fiber-reinforced nylon (CFRN), sustainable manufacturing.