Method of manufacture of a variable density element retainer

Abstract

A single structure usable as a backup shoe or element retainer in a packer assembly for sealing a wellbore can be fabricated using an additive manufacturing process. The single structure can be manufactured to have a high-density region and a low-density region having a density that is lower than the high-density region. The high-density region can include a ribbed-structure to reduce circumferential force applied to the single structure.

What is claimed is: 
     
         1 . A method of manufacturing a variable density element retainer comprising:
 deposing layers of powder onto a plate; and   applying heat to the layers of powder using a laser and in accordance with a pattern to define a high-density region and a low-density region that form a continuous single structure usable to retain a component downhole in a wellbore.   
     
     
         2 . The method of manufacturing of  claim 1 , wherein a layer of powder of some of the layers of powder applied with heat comprises the high-density region and the low-density region. 
     
     
         3 . The method of manufacturing of  claim 1 , wherein applying heat to the layers of powder in accordance with a pattern includes applying heat to define the low-density region in a mesh pattern. 
     
     
         4 . The method of manufacturing of  claim 3 , further comprising:
 removing loose powder that was not applied with heat from within the low-density region in the mesh pattern.   
     
     
         5 . The method of manufacturing of  claim 1 , wherein applying heat to the layers of powder in accordance with a pattern includes applying heat to define the low-density region having a solidified exterior encapsulating loose powder. 
     
     
         6 . The method of manufacturing of  claim 1 , wherein applying heat to the layers of powder in accordance with a pattern includes applying heat to define the low-density region in a solid fill. 
     
     
         7 . The method of manufacturing of  claim 1 , wherein applying heat to the layers of powder in accordance with a pattern includes applying heat to define a ribbed-structure around an outer rim of the high-density region. 
     
     
         8 . The method of manufacturing of  claim 7 , wherein the ribbed-structure comprises at least one protrusion. 
     
     
         9 . The method of manufacturing of  claim 1 , wherein the low-density region comprises a deformable metallic structure. 
     
     
         10 . The method of manufacturing of  claim 1 , wherein applying heat to the layers of powder includes applying heat to form a uniform revolved cross section within the high-density region.