Students Create Reusable 3D-Printed Tool for Abandoned Well Monitoring

Six mechanical engineering seniors at Texas A&M University were tasked by Los Alamos National Laboratory (LANL) to devise a better method for attaching sensors inside abandoned oil and gas wells. These "orphaned" wells pose environmental risks, including methane leaks and groundwater contamination, and LANL is working to enhance their monitoring.

The student team designed a novel solution called the Sensor Positioning and Locking Attachment Tool (S.P.L.A.T.). This flexible, reusable housing is designed to securely affix thin sensors to the interior or exterior of well pipes. Constructed from 3D-printed thermoplastic polyurethane and incorporating magnets, S.P.L.A.T. offers an alternative to traditional, permanent epoxy-based attachment methods.

This new approach simplifies sensor deployment, removal, and reuse, thereby reducing waste and lowering overall costs. The tool's flexible arms create a distinctive "splatter" shape, and its strong magnetic properties cause it to audibly attach to pipes with a "splat" sound, inspiring its memorable name.

Developing S.P.L.A.T. involved overcoming challenges, particularly in preparing and testing the delicate piezoelectric film sensors. The team faced setbacks during the cutting, cleaning, and assembly processes, which required repeated testing and process reevaluation. These experiences, however, proved to be valuable learning opportunities that refined both the design and the team's technical understanding.

The project emphasized collaboration, with team members exchanging ideas and adapting to feedback to create a polished final product. The students also gained practical engineering experience, learning to manage project timelines, order materials, coordinate tasks, and maintain clear documentation, skills directly applicable to future professional endeavors.