Case Study: Shell achieves safer, scalable robotic inspections with Materialise 3D-printed scale models

Shell Brings Robotic Inspection to the Global Energy Industry, Courtesy of 3D Printing

Shell, one of the world’s largest oil and gas companies, needed a way to promote its ExR-1 inspection robot globally without repeatedly transporting the full-size machines. To create portable, realistic demonstrators for showcases, Shell turned to Materialise for a bespoke 3D printing solution that could reproduce the robot’s complex details at scale.

Materialise engineered and printed two ultra-realistic, one-third-scale ExR-1 replicas using a mix of technologies (SLA for glossy body and lenses, SLS with PA-AF for metallic-looking parts, SLS polyamide for tracks), Magics software for file preparation, and detailed finishing and painting. The models are visually identical to the originals, eliminated the need to ship the real robots for demonstrations, and have become effective conversation starters to convince stakeholders and accelerate adoption of Shell’s robotic inspection technology.

Shell

Patrick de Winter

IT Innovation Advisor