Forming facsimile formation core samples using three-dimensional printing

1. A method comprising:

providing an actual formation core sample;

determining an internal anatomy of at least a portion of the actual formation core sample by at least one method selected from the group consisting of x-ray diffraction, near-infrared spectroscopy, energy-dispersive x-ray spectroscopy, and any combination thereof;

selecting an at least one printing material to mimic at least a portion of the internal anatomy of the actual formation core sample;

producing a virtual 3D model of the external anatomy of the actual formation core sample in a computer readable format by at least one method selected from the group consisting of x-ray diffraction, near-infrared spectroscopy, scanning electron microscopy, energy-dispersive x-ray spectroscopy, x-ray computed tomography scan, and any combination thereof,

wherein the virtual 3D model of the external anatomy of the actual formation core sample is represented by successive 2D cross-sectional layers;

providing a 3D printer;

transmitting the virtual 3D model of the external anatomy of the actual formation core sample to the 3D printer;

printing a facsimile core sample using the 3D printer, thereby replicating at least a portion of the external anatomy of the actual formation core sample; and

manually placing at least one sensor within or onto the facsimile core sample during printing.

2. The method of claim 1 , wherein the actual formation core sample comprises damage, and further comprising manipulating a portion of the virtual 3D model of the external anatomy of the actual formation core sample by way of a computer modeling software that simulates the actual formation core sample as it was in the subterranean formation, thereby removing at least a portion of the damage in the virtual 3D model of the external anatomy of the actual core sample such that the printed facsimile core is based at least in part on the manipulated virtual 3D model.

3. The method of claim 1 , wherein the 3D printer prints the facsimile formation core sample using at least one method selected from the group consisting of fused deposition modeling, electron beam freeform fabrication, direct metal laser sintering, electron-beam melting, selective laser melting, selective heat sintering, selective laser sintering, and maskless mesoscale materials deposition.

4. The method of claim 1 , wherein the 3D printer prints the facsimile formation core sample using the printing material selected from the group consisting of a thermoplastic, a eutectic metal, a rubber, a clay, a ceramic, a metal alloy, an elemental metal, a metal clay, a conductive plastic composite, a carbonate, silicon, silicon dioxide, aluminum, magnesium oxide, iron, calcium, and any combination thereof.

5. The method of claim 1 , wherein the at least one sensor is selected from the group consisting of a density sensor, a capacity sensor, a viscosity sensor, a resistivity sensor, an optical sensor, a temperature sensor, a flow rate sensor, a scale sensor, a strain sensor, a pressure sensor, a sound sensor, a flux sensor, a piezoresistive sensor, a capacitance sensor, and any combination thereof.

6. The method of claim 1 , wherein the at least one sensor emits an output signal in the form of at least one of an electromagnetic signal and an acoustic signal.

7. The method of claim 1 , wherein a fluid is tested with the facsimile core sample to determine at least a portion of one analyses selected from the group consisting of flow rate analysis, fluid compatibility analysis, permeability regain analysis, leakoff analysis, damage removal analysis, acidizing analysis, sanding tendency analysis, perforation analysis, erosion analysis, consolidation analysis, diversion analysis, conformance analysis, and any combination thereof, thereby determining the effects of the fluid therein.

8. A method comprising:

providing an actual formation core sample;

determining an internal anatomy of at least a portion of the actual formation core sample by at least one method selected from the group consisting of x-ray diffraction, near-infrared spectroscopy, energy-dispersive x-ray spectroscopy, and any combination thereof;

selecting at least a first printing material to mimic at least a portion of the internal anatomy of the actual formation core sample;

producing a virtual 3D model of an external anatomy of the actual formation core sample in a computer readable format by at least one method selected from the group consisting of x-ray diffraction, near-infrared spectroscopy, scanning electron microscopy, energy-dispersive x-ray spectroscopy, x-ray computed tomography scan, and any combination thereof,

wherein the virtual 3D model of the external anatomy of the actual formation core sample is represented by successive 2D cross-sectional layers;

manipulating a portion of the virtual 3D model of the external anatomy of the actual formation core sample to include at least one virtual 3D sensor model, thereby forming a virtual 3D model of the external anatomy of the actual formation core sample comprising at least one sensor;

providing a 3D printer;

transmitting the virtual 3D model of the external anatomy of the actual formation core sample comprising at least one sensor to the 3D printer; and

printing a facsimile core sample comprising at least one sensor using the 3D printer, thereby replicating the external anatomy of the actual formation core sample and the at least one printed sensor.

9. The method of claim 8 , wherein the actual formation core sample comprises damage, and further comprising manipulating a portion of the virtual 3D model of the external anatomy of the actual formation core sample by way of a computer modeling software that simulates the actual formation core sample as it was in the subterranean formation, thereby removing at least a portion of the damage in the virtual 3D model of the external anatomy of the actual core sample such that the printed facsimile core is based at least in part on the manipulated virtual 3D model.

10. The method of claim 8 , wherein the 3D printer prints the facsimile core sample comprising the at least one printed sensor using at least one method selected from the group consisting of fused deposition modeling, electron beam freeform fabrication, direct metal laser sintering, electron-beam melting, selective laser melting, selective heat sintering, selective laser sintering, maskless mesoscale materials deposition.

11. The method of claim 8 , wherein the 3D printer prints the facsimile core sample using the first printing material and the at least one printed sensor using a second printing material.

12. The method of claim 11 , wherein the first printing material is selected from the group consisting of a thermoplastic, a eutectic metal, a rubber, a clay, a ceramic, a metal alloy, an elemental metal, a metal clay, a conductive plastic composite, a carbonate, silicon, silicon dioxide, aluminum, magnesium oxide, iron, calcium, an any combination thereof.

13. The method of claim 11 , wherein the second printing material is selected from the group consisting of an optical material, a glass material, a plastic material, a conductive plastic composite material, a carbon black material, a copper material, and any combination thereof.

14. The method of claim 8 , wherein the at least one printed sensor is selected from the group consisting of a density sensor, a capacity sensor, a viscosity sensor, a resistivity sensor, an optical sensor, a temperature sensor, a flow rate sensor, a scale sensor, a strain sensor, a pressure sensor, a sound sensor, a flux sensor, a piezoresistive sensor, a capacitance sensor, and any combination thereof.

15. The method of claim 8 , further comprising manually placing at least one sensor within or onto the replica of the formation core sample comprising at least one printed sensor during printing.

16. The method of claim 15 , wherein the at least one sensor manually placed is selected from the group consisting of a density sensor, a capacity sensor, a viscosity sensor, a resistivity sensor, an optical sensor, a temperature sensor, a flow rate sensor, a scale sensor, a strain sensor, a pressure sensor, a sound sensor, a flux sensor, a piezoresistive sensor, a capacitance sensor, and any combination thereof.

17. The method of claim 8 , wherein a fluid is tested with the facsimile core sample to determine at least a portion of one analyses selected from the group consisting of flow rate analysis, fluid compatibility analysis, permeability regain analysis, leakoff analysis, damage removal analysis, acidizing analysis, sanding tendency analysis, perforation analysis, erosion analysis, consolidation analysis, diversion analysis, conformance analysis, and any combination thereof, thereby determining the effects of the fluid therein.