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3D-Cloning of Core Plug Structures: Insights and Challenges into FDM and DLP Printing Based on Microtomography Data

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dc.contributor.authorKadyrov, R. I.
dc.contributor.authorNguyen, T. H.
dc.contributor.authorStatsenko, E. O.
dc.contributor.authorKharin, N. V.
dc.date.accessioned2026-01-23T16:31:38Z
dc.date.available2026-01-23T16:31:38Z
dc.date.issued2025
dc.description.abstractThis study explores the use of FDM (Fused Deposition Modeling) and DLP (Digital Light Processing) 3D printing techniques to create accurate replicas of core plugs from reservoir rock structures based on µCT (microtomography) scans. Due to the challenges in obtaining core plug samples for reservoir characterization, this research aims to develop a cost-effective and reusable alternative by replicating the pore structure of natural rocks for use in experimental studies. A carbonate core plug was µCT-scanned to obtain a high-resolution 3D digital model of its pore structure, which was then digitally processed to simplify its complex pore geometry for 3D printing. The model was printed using FDM with 0.2 mm and 0.4 mm nozzles, as well as DLP techniques. Both methods were evaluated by re-scanning the printed samples with µCT and analyzing their structural, porosity, and permeability characteristics. FDM printing demonstrated the ability to replicate larger pore structures, but the presence of interlayer gaps resulted in inflated porosity and permeability values compared to the original core plug, and fine pore features were inconsistently replicated across multiple prints. DLP printing, while more accurate in capturing morphology and finer details, also exhibited variability in the reproduction of small pore elements. Furthermore, cracks were observed in DLP samples due to stresses during resin curing, and the retention of residual resin in pores affected permeability and reduced effective porosity. The study highlights the limitations of both FDM and DLP methods in fully reproducing the complexity of pore networks, particularly at fine scales. The results point to the need for technological improvements in both methods to enhance the accuracy and reproducibility of 3D-printed core replicas.
dc.description.urihttp://sv-journal.org/2025-1/05/en.pdf
dc.identifier.citationR. I. Kadyrov, T. H. Nguyen, E. O. Statsenko, N.V. Kharin. 3D-Cloning of Core Plug Structures: Insights and Challenges into FDM and DLP Printing Based on Microtomography Data. (2025). Scientific Visualization 17.1: 45 - 64, DOI: 10.26583/sv.17.1.05
dc.identifier.doi10.26583/sv.17.1.05
dc.identifier.urihttps://openrepository.mephi.ru/handle/123456789/40231
dc.publisherНИЯУ МИФИ
dc.subjectDLP
dc.subjectFDM
dc.subject3D-printing
dc.subjectµCT
dc.subjectPorous structure
dc.subjectReservoir
dc.subjectCore plug
dc.subjectReplication
dc.subject3D-cloning
dc.title3D-Cloning of Core Plug Structures: Insights and Challenges into FDM and DLP Printing Based on Microtomography Data
dc.typeArticleru
dspace.entity.typePublication
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