Cold Metal Fusion Is the Future of Producing Downhole Impulse Tools

Downhole impulsers are critical components in oil and gas drilling, enabling vibration-assisted drilling to reduce friction, improve rate of penetration, and extend tool life. These parts face some of the harshest conditions imaginable: extreme pressures, abrasive fluids, and punishing cyclic loads. Traditional manufacturing methods—such as casting, machining, or laser powder bed fusion (L-PBF)—often fall short when it comes to balancing performance, cost, and scalability.

Enter Cold Metal Fusion (CMF) 3D Printing: a breakthrough additive manufacturing technology that combines the flexibility of polymer SLS printing with proven powder metallurgy processes. For downhole implulse tools, CMF offers distinct advantages:

1. Geometries That Unlock Performance

Downhole impulse tools rely on internal fluid channels and complex vane designs that optimize vibration frequency and amplitude. Machining these internal geometries from solid stock is nearly impossible, and L-PBF often struggles with supports, thermal stress, and surface quality.

• CMF enables support-free printing of intricate channels and shrouded features, opening the door to new impeller and impulser designs optimized for flow and fatigue resistance.

2. Material Strength for Harsh Conditions

CMF parts are built from the same alloys trusted in oilfield applications—such as Ti-6Al-4V, Inconel 625, and other high-temperature, corrosion-resistant materials. Because sintering follows conventional powder metallurgy, the final components achieve:

• Near-wrought density and grain structure
• High tensile strength and fatigue resistance
• Corrosion performance suitable for abrasive drilling fluids

3. Scalability That Matches Oilfield Demand

The oil and gas sector consumes millions of replacement parts annually, and impulsers are no exception. Unlike laser-based additive systems that scale slowly and cost heavily, CMF offers:

• Batch production in SLS printers—dozens of impulsers per build
• Low capital cost compared to multi-laser L-PBF systems
• Proven repeatability across global powder metallurgy supply chains

4. Cost Advantages Over Traditional Manufacturing

With CMF, the cost equation changes:

• Less machining waste compared to billet stock
• Reduced post-processing thanks to fine powder starting surface
• Lower energy input, driving down per-part costs

For downhole tools, where margins matter and replacement cycles are constant, CMF helps operators achieve better economics without sacrificing performance.

5. Made in the U.S.A.

Supply chain resilience is top of mind for the oilfield service sector. By leveraging CMF, production can be localized, reducing reliance on overseas foundries or machining vendors. This means faster turnaround, reduced lead times, and increased control over part quality.

The Bottom Line

Downhole impulsers demand strength, precision, and scalability. Cold Metal Fusion uniquely delivers all three—unlocking new designs, improving durability, and reducing costs at scale. For oilfield service companies seeking the next competitive edge, CMF represents not just an alternative, but a step change in how these mission-critical components are produced.

👉 At CADmore Metal, we’re leading the way in bringing CMF to the oil and gas industry. If you’d like to explore how this technology can transform your downhole impulsers, reach out—we’d love to collaborate.