3D Printing FilamentsAM for EnergyIndustrial Additive ManufacturingMaterials

Baker Hughes will produce 3D printing filaments from coal wastes

The U.S. DOE will fund several projects to develop coal-based materials for AM

Stay up to date with everything that is happening in the wonderful world of AM via our LinkedIn community.

Baker Hughes’ Energy Innovation Center, Additive Manufacturing Technology Center, and energy transition teams supported a project proposal the U.S. Department of Energy. Baker Hughes’ project of “Coal-Enhanced PEEK Filament Production for Additive Manufacturing in Industrial Services” was selected to receive funding to develop innovative ways to use coal wastes.

The DOE project is based on the idea that in order to extract the full economic value from coal wastes in a sustainable way, innovation is needed. The National Energy Technology Laboratory’s (NETL) Carbon Ore Processing Program sought to address and deliver solutions to this challenge by supporting novel technologies that produce valuable products from coal waste-derived sources through laboratory- and pilot-scale R&D.

Funded with over $1.1 million, the Baker Hughes project was among seven projects the DOE selected to support the development of new and safe uses for coal wastes. While BH is one of the biggest players in global Oil & Gas industry, the company has been investing heavily in technologies—especially additive manufacturing—to make energy generation cleaner and more sustainable.

Baker Hughes Energy Transition LLC (Houston, Texas) and its team now plan to enhance polyether-ether-ketone (PEEK) filaments, a critical feedstock used in additive manufacturing, with coal-derived graphene-like materials. The scope of work will focus on FFF material extrusion, a highly accessible AM process. The study will manufacture a suite of selected parts, including seals, spacers, washers and backup rings using PEEK and coal-enhanced PEEK to baseline and compare overall performance.

7 million for 7 projects to use coal wastes

The U.S. Department of Energy’s (DOE) Office of Fossil Energy and Carbon Management (FECM) announced nearly $7 million in funding for seven projects that will develop coal-based filaments or resins for additive manufacturing and advance research and development (R&D) of coal-derived graphite. This investment supports the development of new and safe uses for coal wastes, which in turn will spur the creation of good-paying jobs in frontline communities as the nation transitions to 100 percent clean electricity by 2035.

Baker Hughes will produce 3D printing filaments from coal wastes The projects selected, to be managed by NETL’s Carbon Ore Processing Program, will use materials derived from coal wastes like tailings and ash for additive manufacturing via extrusion 3D printing and to produce graphite that is used to manufacture batteries, fuel cells and energy storage devices. These applications align with the goals of the Biden-Harris Administration to expand and develop existing and new environmentally sound and safe uses for coal waste and deploy these advanced technologies to help support economically distressed power plant and coal communities.

“West Virginia coal has powered the American economy for decades, and today’s funding announcement will advance efforts to use coal-waste in developing valuable products, supporting our environmental objectives and the coal value chain. West Virginia’s abundant coal resources have proven attributes that make it a prime feed-stock for high-end valuable products and we need to ensure we are investing the resources needed to harness the full value of this important natural resource in the cleanest and most efficient way possible. Doing so has the potential to provide new economic opportunities and revitalize traditional energy-producing communities who have been hit the hardest by the energy transition,” said U.S. Senator Joe Manchin, Chairman of the Senate Energy and Natural Resources Committee.

“Ohio is leading the way on industrial energy efficiency,” said U.S. Senator Sherrod Brown. “These federal funds will allow us to continue to invest in cutting edge energy technology so that we’re creating local jobs and improving our economy in a responsible and sustainable way while developing the next generation of innovative technology.”

Baker Hughes will produce 3D printing filaments from coal wastes “The Energy & Environmental Research Center at the University of North Dakota is working to find innovative ways to help North Dakota’s lignite coal producers meet the increasing demands for lithium-ion batteries,” said U.S. Senator Kevin Cramer. “I’m grateful their work to support this vital sector of our energy industry is receiving the backing of the Department of Energy with today’s award.”

“Given North Dakota’s abundant lignite resources, this funding to EERC will help advance new research and develop additional ways to utilize coal-based products to help meet the growing demand for lithium-ion batteries,” said U.S. Senator John Hoeven.

“Developing a market for coal-based products is vital for the future of our coal communities, and can provide a vital lifeline for miners and their families,” said U.S. Representative David B. McKinley, P.E. “I’m especially proud to see Touchstone on the leading edge of this work. Their research has exciting potential in everything from aerospace to building materials. This funding is vital to continue their important work.”

“West Virginia’s coal miners have worked hard to keep the lights on and power this country for generations. Research and development of advance coal technologies is important not only to the future of coal, but also to the opportunities that are available for West Virginians. Touchstone has been a leader in revolutionizing new technology that reduces waste from coal facilities, which was why I was proud to advocate on behalf of this project last August. Coal remains the lifeblood of West Virginia’s energy economy, and this funding will help us continue to grow and strengthen this important sector,” U.S. Senator Shelley Moore Capito said.

Selected projects

A detailed list can be found here.

  • Coal-Enhanced PEEK Filament Production for Additive Manufacturing in Industrial Services — Baker Hughes Energy Transition LLC (Houston, Texas)
  • Fused Deposition Modeling Additive Manufacturing of Carbonized Structures Via Waste-Enhanced Filaments — Ohio University (Athens, Ohio)
  • Coal Waste-Enhanced Filaments for Additive Manufacturing of High-Temperature Plastics and Ceramic Composites — Semplastics EHC (Oviedo, Florida)
  • Lab-scale Production of Coal-Derived Graphene Particle Bonded Filaments — University of Delaware (Newark, Delaware)
  • Utilization of Carbon Supply Chain Wastes and Byproducts to Manufacture Graphite for Energy Storage Applications — Ohio University (Athens, Ohio)
  • Molded Graphite Products Synthesized from Waste Coal — Touchstone Research Laboratory (Triadelphia, West Virginia)
  • Advanced Processing of Coal and Coal Waste to Produce Graphite for Fast-Charging Lithium-Ion Battery Anode — University of North Dakota Energy & Environmental Research Center (Grand Forks, North Dakota)


Composites AM 2024

746 composites AM companies individually surveyed and studied. Core composites AM market generated over $785 million in 2023. Market expected to grow to $7.8 billion by 2033 at 25.8% CAGR. This new...

Davide Sher

Since 2002, Davide has built up extensive experience as a technology journalist, market analyst and consultant for the additive manufacturing industry. Born in Milan, Italy, he spent 12 years in the United States, where he completed his studies at SUNY USB. As a journalist covering the tech and videogame industry for over 10 years, he began covering the AM industry in 2013, first as an international journalist and subsequently as a market analyst, focusing on the additive manufacturing industry and relative vertical markets. In 2016 he co-founded London-based VoxelMatters. Today the company publishes the leading news and insights websites VoxelMatters.com and Replicatore.it, as well as VoxelMatters Directory, the largest global directory of companies in the additive manufacturing industry.

Related Articles

Leave a Reply

Your email address will not be published. Required fields are marked *

Back to top button
Close Popup
Privacy Settings saved!
Privacy Settings

When you visit any web site, it may store or retrieve information on your browser, mostly in the form of cookies. Control your personal Cookie Services here.

These cookies are necessary for the website to function and cannot be switched off in our systems.

Technical Cookies
In order to use this website we use the following technically required cookies
  • wordpress_test_cookie
  • wordpress_logged_in_
  • wordpress_sec

Decline all Services
Accept all Services


Join our 12,000+ Professional community and get weekly AM industry insights straight to your inbox. Our editor-curated newsletter equips executives, engineers, and end-users with crucial updates, helping you stay ahead.