Case Study: Downhole Emerging Technologies achieves award-winning geothermal innovation with Protolabs DMLS 3D printing

Metal 3D Printing Provides Design Freedom, Durability in Geothermal Energy Application

Downhole Emerging Technologies (DET), a Houston-based startup, faced the challenge of developing a geothermal packer tool capable of withstanding extreme temperatures of 700°F, where traditional rubber or plastic components fail. Working with Protolabs, they needed a fast, durable manufacturing solution to meet the aggressive deadlines of a U.S. Department of Energy competition.

Protolabs utilized its direct metal laser sintering (DMLS) 3D printing service to quickly produce complex, iterated metal parts from heat-resistant alloys like Inconel 718. This enabled the rapid prototyping of DET's innovative accordion-like design, which could not be machined. As a direct result, DET's Diamond ETIP tool won the grand prize in the DOE competition, including a $500,000 cash award, and is now on a path toward market launch.

Downhole Emerging Technologies

Ken Havlinek

Founder