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.

The present disclosure provides three-dimensional (3D) printing processes, apparatuses, software, and systems for the production of at least one desired 3D object. The 3D printer system (e.g., comprising a processing chamber, build module, or an unpacking station) described herein may retain a desired (e.g., inert) atmosphere around the material bed and/or 3D object at multiple 3D printing stages. The 3D printer described herein comprises one or more build modules that may have a controller separate from the controller of the processing chamber. The 3D printer described herein comprises a platform that may be automatically constructed. The invention(s) described herein may allow the 3D printing process to occur for a long time without operator intervention and/or down time.

A 3-dimensional printing system for manufacturing a part is provided. The system includes a building platform having a deposited pattern of metal powder, a sand dispensing nozzle selectively supplying sand to the building platform, a binder dispensing nozzle selectively supplying binder material to the building platform, a robotic arm supporting one or more of the sand dispensing nozzle and the binder dispensing nozzle, the robotic arm moving the one or more of the sand dispensing nozzle and the binder dispensing nozzle, and a processor controlling the robotic arm to position the one or more of the sand dispensing nozzle and the binder dispensing nozzle relative to the deposited pattern of metal powder and control the sand dispensing nozzle and the binder dispensing nozzle to supply powdered sand and binder, respectively, based on a Computer Aided Drafting file associated with the part.

A 3-dimensional printing system for manufacturing a part is provided. The system includes a building platform having a deposited pattern of metal powder, a sand dispensing nozzle selectively supplying sand to the building platform, a binder dispensing nozzle selectively supplying binder material to the building platform, a robotic arm supporting one or more of the sand dispensing nozzle and the binder dispensing nozzle, the robotic arm moving the one or more of the sand dispensing nozzle and the binder dispensing nozzle, and a processor controlling the robotic arm to position the one or more of the sand dispensing nozzle and the binder dispensing nozzle relative to the deposited pattern of metal powder and control the sand dispensing nozzle and the binder dispensing nozzle to supply powdered sand and binder, respectively, based on a Computer Aided Drafting file associated with the part.

Gradient refractive index lenses (GRI-Ls) and methods of fabricating the same are provided. GRI-Ls can be fabricated by stereolithography (SLA) and/or photo-assisted, thermal-assisted, and/or other laser-based curing from at least two precursors with a preset refractive index gradation along the planar axis. These lenses are self-focusing lenses and may be convergent or divergent for decreasing and increasing refractive indices from the center, respectively. Rather than a gradation in lens thickness from the center, the GRI-Ls can have a gradation of composition from the center.

A 3D printed proppant includes a core having support bars extending from the core to a shell, the shell encapsulating the core and the support bars. Another 3D printed proppant includes a porous core and a shell encapsulating the porous core, where the porous core has a porosity from 25% to 75%. The 3D printed proppant has a particle size from 8 mesh to 140 mesh. The core, the support bars, the porous core, the shell, or combinations thereof includes metal, polymer, ceramic, composite, or combinations thereof. Additionally, a method for producing a 3D printed proppant is provided.

In an example of a three-dimensional (3D) printing method, a ceramic build material is applied. A detailing agent fluid is applied to a portion of the ceramic build material. The detailing agent fluid includes a cationic polymer. A liquid functional material, including an anionically stabilized susceptor material, is applied to another portion of the ceramic build material that is in contact with the portion of the ceramic build material having the detailing agent fluid thereon, such that at least some of the anionically stabilized susceptor material reacts with at least some of the cationic polymer that is in contact therewith to prevent spreading of the anionically stabilized susceptor material.

A composition can comprise particles comprising 5% by weight (wt %) or more, a photo-initiator, a curing agent, a dispersant, and an organic binder. The composition can be substantially solvent-free. In some embodiments, particles comprise 65 wt % or more. In some embodiments, the curing agent comprises dipropylene-glycol diacrylate. In some embodiments, the dispersant comprises a phosphate ester. In some embodiments, the organic binder comprises isobornyl methacrylate. In some embodiments, the composition comprises a viscosity from about 100 milliPascal-seconds to about 7,000 milliPascal-seconds. Methods of making a green body can comprise creating a composition, printing the green body using the composition, and curing the green body. Method of making a printed article can comprise creating a composition, printing a green body using the composition, curing the green body, heating the green body to remove the organic binder to form a porous article, and sintering the porous article to form the printed article.

A ceramic subassembly manufactured by a 3D-printing process is described. The ceramic subassembly comprises a ceramic substrate having a sidewall extending to spaced apart first and second end surfaces. At least one via extends through the substrate from the ceramic substrate first end surface to the ceramic substrate second end surface. In cross-section, the via has a square-shape with rounded corners.

A system for applying a building material, including: a movement device for modifying a site of application in a space; a first component of the building material; a second component of the building material; a mixer for mixing the first component and the second component, the mixer including a drive module with a first coupling element and a mixing chamber module with a second coupling element, the drive module and the mixing chamber module being detachably embodied, and the drive module and the mixing chamber module being actively interconnected in an application state of the system by means of the coupling elements.