The oil and gas industry has always been a study in endurance, as its infrastructure spans oceans, deserts, and frozen landscapes, built to operate under punishing conditions for decades.  But even the strongest systems are not immune to the passage of time and shifting pressures. Equipment ages, supply chains evolve, and the energy landscape itself is changing as companies prepare for a lower-carbon future.

In this transition, material science and engineering is quietly reshaping Oil & Gas, enabling it to meet the twin challenges of sustaining legacy assets and preparing for entirely new operational demands. In this article, we observe the advancements of two innovations: the use of additive manufacturing to address parts obsolescence and the development of hydrogen-ready steel to enable the fuels of tomorrow.

additive manufacturing in the face of obsolete components

Oil and gas infrastructure is built for longevity, with many systems expected to operate for thirty years or more. However, the supply chain that support these systems rarely remains static for so long. Over time, certain components are discontinued as manufacturers move on to newer technologies or decide that producing older parts is no longer profitable.

This creates a quiet but serious risk for operators, as a single discontinued valve or connector can jeopardize an entire operation, forcing costly downtime while alternatives are sourced or fabricated. Traditionally, companies have tried to manage this risk by stockpiling spare parts or commissioning custom replacements, both of which come with long lead times and high costs. These approaches, though necessary, have often been inefficient and reactive rather than truly resilient.

Additive manufacturing has begun to change that dynamic, providing companies with the opportunity to use modern 3D printing technology to produce critical components on demand from digital models. At scale, this technology can eliminate the logistical challenges of transporting rare parts to remote sites and significantly shorten the time between identifying a problem and deploying a solution.

Case Examples:

In 2022, Shell Nigeria demonstrated the potential of this approach by successfully producing a replacement part through 3D printing for one of its offshore operations. This resulted in an 87% turnaround efficiency, cutting lead time from 16 to just 2 weeks, and lowering cost by 90%, keeping production running smoothly without disruption.

Equinor in Norway has been moving toward digital spare parts inventory, replacing the need for massive physical warehouses with a system that allows parts to be printed as needed. The Norwegian company is collaborating with its Oil & Gas counterparts like Total Energies, Shell, ConocoPhillips, and others to implement a digital inventory strategy. In one example at the Oseberg field center, delivery time was cut from 40 to 10 weeks to replace five hydraulic valve blocks.

This evolution represents a shift in philosophy for engineers in oil & gas because maintenance strategies can now be built around digital flexibility, where critical components are never truly out of reach. In an industry where downtime can translate into millions of dollars lost per day, this is a fundamental step toward resilience.

Hydrogen-ready steel for the Future of energy

While additive manufacturing addresses the vulnerabilities of the supply chain, energy transition introduces a different kind of ambition for the industry: preparing infrastructure for a future where hydrogen plays a central role.

Hydrogen is increasingly viewed as a vital part of the global decarbonization effort, particularly for industries like heavy transport and manufacturing that are difficult to electrify. Oil and gas companies are investing heavily in hydrogen production and distribution networks as they look to expand their role in a lower-carbon energy system.

However, hydrogen is not an easy fuel to handle. When it flows through steel pipelines, hydrogen atoms can seep into the metal, reducing its toughness and leading to a condition known as hydrogen embrittlement. Over time, this process can cause cracks and catastrophic failures. The problem is magnified when transporting pure hydrogen at high pressures, as opposed to blending it with natural gas in existing pipelines. To overcome this challenge, material scientists and manufacturers have been developing new generations of steel and protective coatings specifically designed to withstand hydrogen’s effects.

Case Examples:

In 2024, ArcelorMittal’s Roman mill in Europe received certification for producing hydrogen-ready tubular products, signaling that the technology for pure hydrogen service is ready for commercial deployment. Similarly, EVRAZ North America announced the production of high strength welded line pipe engineered to safely handle the demands of high-pressure hydrogen transport.

Last year, Triton Hydrogen introduced Tritonex, a barrier coating designed to prevent hydrogen from permeating pipeline walls. This type of coating is a vital tool for operators seeking to extend the life of existing infrastructure while new hydrogen-specific networks are built.

These developments mean that some existing natural gas pipelines may be adapted to carry hydrogen blends, while others will need to be replaced entirely to safely transport pure hydrogen. Planning these transitions requires foresight, rigorous materials testing, and an understanding of how today’s design decisions will affect tomorrow’s energy landscape. The stakes are high: the pipelines being laid today must remain safe and reliable for the evolving mix of low-carbon alternatives that the future will demand.

The Paradox of Resilience towards Obsolescence and the Role of Material Engineering

In an operating environment shaped by the pressures of energy transition and external disruptions such as supply chain instability, the oil & gas industry occupies a uniquely complex position. It is being asked to be both a cornerstone of current energy security and a key stakeholder in its own obsolescence: evolving toward lower-carbon models while maintaining the reliability that underpins the global economy.

Within this paradox, the science behind engineering elements has become central to the industry’s capacity for resilience. It provides innovative solutions for the sector to sustain itself today and prepare for what comes next.

Additive manufacturing is providing the flexibility to reproduce obsolete parts and mitigate supply vulnerabilities that once led to costly downtime. At the same time, innovations in hydrogen-resilient steel are fortifying the physical foundations of a future energy system built on cleaner fuels. Each advancement, whether digital or metallurgical, represents a form of continuity, ensuring that the assets built to power yesterday’s world can evolve to meet the demands of tomorrow’s.

As the industry navigates this era of transformation, the scope of resilience is expanding to encompass the ability to reimagine materials, redesign processes, and repurpose existing assets for new energy realities.

About the Author:

Max Bastiaansen is a mechanical engineer. He is the European Business Development Manager at Nord-Lock Group, where he plays a pivotal role in bridging the gap between engineering and commercial applications within the tensioning business.