Patent Publication Number: US-2021164319-A1

Title: 3d printed tool with integral stress concentration zone

Description:
PRIORITY 
     The present application is a Divisional patent application of U.S. patent application Ser. No. 16/072,611, filed on Jul. 25, 2018, which is a U.S. National Stage patent application of International Patent Application No. PCT/US2016/022268, filed on Mar. 14, 2016, the benefit of which is claimed and the disclosure of which is incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates generally to subsurface equipment that is at least partially manufactured using additive manufacturing, such as 3D printing, and more specifically, to a printed tool having an integral stress concentration zone. 
     BACKGROUND 
     Often, one portion of a subsurface tool is designed to separate from another portion of the subsurface tool when a predetermined force, such as a shear force or tensile force, is applied to the tool when the tool is down-hole. This separation allows for relative movement between the two portions. Whether the tool is a single-component tool or a multi-component tool, the predetermined force to separate the portions of the tool is generally proportional to an outer dimension of the tool. It is often desired to separate the portions of the tool with a force that is less than the predetermined force without otherwise affecting the performance and operation of the tool. Additionally, it is generally desired to reduce the number of components in the subsurface tool. 
     The present disclosure is directed to printed subsurface equipment, such as a printed tool having an integral stress concentration zone. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Various embodiments of the present disclosure will be understood more fully from the detailed description given below and from the accompanying drawings of various embodiments of the disclosure. In the drawings, like reference numbers may indicate identical or functionally similar elements. 
         FIG. 1  is a schematic illustration of an offshore oil or gas production platform operating a printed tool with an integral stress concentration zone, according to an exemplary embodiment of the present disclosure; 
         FIG. 2  is a perspective view of a partial cut-out of the tool of  FIG. 1  when the tool is a plug, according to an exemplary embodiment of the present disclosure; 
         FIG. 3A  is a sectional view of the plug of  FIG. 2  in a first configuration, according to an exemplary embodiment of the present disclosure; 
         FIG. 3B  is a sectional view of the plug of  FIG. 2  in a second configuration, according to an exemplary embodiment of the present disclosure; 
         FIG. 4  is a perspective view of a partial cut-out view of the tool of  FIG. 1  when the tool is a shear sleeve, according to an exemplary embodiment of the present disclosure; 
         FIG. 5A  is a sectional view of the shear sleeve of  FIG. 4  in a first configuration, according to an exemplary embodiment of the present disclosure; 
         FIG. 5B  is a sectional view of the shear sleeve of  FIG. 4  in a second configuration, according to an exemplary embodiment of the present disclosure; 
         FIG. 6A  is a sectional view of the shear sleeve of  FIG. 4 , according to another exemplary embodiment of the present disclosure; 
         FIG. 6B  is another sectional view of the shear sleeve of  FIG. 6A , according to an exemplary embodiment of the present disclosure; 
         FIG. 7A  is a sectional view of the tool of  FIG. 1  when the tool is a shear pin, according to an exemplary embodiment of the present disclosure; 
         FIG. 7B  is another sectional view of the pin of  FIG. 7A , according to an exemplary embodiment of the present disclosure; 
         FIG. 8A  is a sectional view of the shear pin of  FIGS. 7A and 7B  in a first configuration, according to an exemplary embodiment of the present disclosure; 
         FIG. 8B  is a sectional view of the shear pin of  FIG. 8A  in a second configuration, according to an exemplary embodiment of the present disclosure; 
         FIG. 9A  illustrates a perspective view of the tool of  FIG. 1  when the tool is a millable packer, according to an exemplary embodiment of the present disclosure; 
         FIG. 9B  is a sectional view of the tool of  FIG. 9A , according to an exemplary embodiment; 
         FIG. 9C  is another sectional view of the tool of  FIG. 9A , according to an exemplary embodiment; 
         FIG. 10  illustrates an additive manufacturing system, according to an exemplary embodiment; and 
         FIG. 11  is a diagrammatic illustration of a node for implementing one or more exemplary embodiments of the present disclosure, according to an exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Illustrative embodiments and related methods of the present disclosure are described below as they might be employed in a printed tool with an integral stress concentration zone and method of operating the same. In the interest of clarity, not all features of an actual implementation or method are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers&#39; specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. Further aspects and advantages of the various embodiments and related methods of the disclosure will become apparent from consideration of the following description and drawings. 
     The foregoing disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Further, spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper,” “uphole,” “downhole,” “upstream,” “downstream,” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the apparatus in use or operation in addition to the orientation depicted in the figures. For example, if the apparatus in the figures is turned over, elements described as being “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” may encompass both an orientation of above and below. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly. 
       FIG. 1  is a schematic illustration of an offshore oil and gas platform generally designated  10 , operably coupled by way of example to a printed tool having an integral stress concentration zone according to the present disclosure. Such an assembly could alternatively be coupled to a semi-sub or a drill ship as well. Also, even though  FIG. 1  depicts an offshore operation, it should be understood by those skilled in the art that the apparatus according to the present disclosure is equally well suited for use in onshore operations. By way of convention in the following discussion, though  FIG. 1  depicts a vertical wellbore, it should be understood by those skilled in the art that the apparatus according to the present disclosure is equally well suited for use in wellbores having other orientations including horizontal wellbores, slanted wellbores, multilateral wellbores or the like. 
     Referring still to the offshore oil and gas platform example of  FIG. 1 , a semi-submersible platform  15  may be positioned over a submerged oil and gas formation  20  located below a sea floor  25 . A subsea conduit  30  may extend from a deck  35  of the platform  15  to a subsea wellhead installation  40 , including blowout preventers  45 . The platform  15  may have a hoisting apparatus  50 , a derrick  55 , a travel block  60 , a hook  65 , and a swivel  70  for raising and lowering pipe strings, such as a substantially tubular, axially extending tubing string  75 . As in the present example embodiment of  FIG. 1 , a wellbore  80  extends through the various earth strata including the formation  20 , with a portion of the wellbore  80  having a casing string  85  cemented therein. Disposed in the wellbore  80  is a completion assembly  90 . Generally, the assembly  90  may be any one or more completion assemblies, such as for example a hydraulic fracturing assembly, a gravel packing assembly, etc. The assembly  90  may be coupled to the tubing string  75  and may include the printed downhole tool  95  (shown in greater detail in  FIG. 2 ) 
       FIG. 2  illustrates a perspective view of a cut-out of the tool  95  when the tool is a plug  100 . The plug  100  may be coupled to any one of a variety of downhole tools that form a portion of the tubing string  75 , such as a packer, a seal bore extension, a mill-out extension or tailpipe. Regardless, the plug  100  is formed from an integrally formed single-component body  105  having a top portion  110  and an opposing bottom portion  115  in an axial direction indicated by the numeral  117 A or an opposing axial direction indicated by the numeral  117 B in the  FIG. 2 . The top portion  110  has a coupler  120  that couples the plug to the tubing string  75 . For example, the coupler  120  is internally formed threads, but may be externally formed threads, pins, or any other similar coupler suitable for attaching the plug  100  to the tubing string  75 . Generally, the top portion  110  forms a tubular  122  that defines an interior passageway  125 . The bottom portion  115  includes a cap  130  that extends across the interior passageway  125  to block the interior passageway  125 . In an exemplary embodiment, a plurality of chambers  135  is formed within the body  105  at an interface  139  of the cap  130  and the tubular  122 . In an exemplary embodiment, the interface  139  is a zone of the body  105  that is adjacent at least one internal chamber of the plurality of internal chambers  135 . In an exemplary the plurality of chambers  135  creates a stress concentration zone in the body  105  at the interface  139  when a plug  100  is subjected to one or more stresses. 
       FIG. 3A  illustrates the plug  100  in a run-in or first configuration, in which the body  105  is integrally formed such that the cap  130  is integrally formed to the tubular  122  to block the interior passageway  125 . In the first configuration, the plug  100  is capable of withstanding a first predetermined range of forces to the end cap  130  in the direction  117 B, which places the body  105  of the plug  100  under compressive stress. In an exemplary embodiment, the first predetermined range of forces may be applied via hydraulically or mechanically. Additionally, the plug  100  is capable of withstanding a second predetermined range of forces applied to the end cap  130  in the direction  117 A, which places the body  105  of the plug  100  in tensile stress. Thus, the plug  100  is a bi-directional pressure plug that prevents bi-directional flow while in the first configuration. Additionally, as the body  105  forms both the tubular  122  and the end cap  130 , the plug  100  is a single component bi-direction pressure plug. 
       FIG. 3B  illustrates the plug  100  in an actuated or second configuration, in which the end cap  130  is detached from the tubular  122 . In an exemplary embodiment, and when a force is applied in the direction  117 A that exceeds the second predetermined range of forces, the end cap  130  is separated from the tubular  122  along the interface  139 . That is, when a force is applied in the direction  117 A that results in tensile stress occurring in the interface  139  that exceeds a fracture strength or breaking strength of the material forming the body  105 , then the end cap  130  breaks away from the tubular  122  to allow a fluid to flow through the fluid passage  125 . 
     In one or more exemplary embodiments, at least one chamber within the plurality of chambers  135  is an internal chamber. In one or more exemplary embodiments, an internal chamber is a chamber that is spaced from an external surface  105   a  of the body  105  or is a chamber that does not penetrate the external surface  105   a . In one or more exemplary embodiments, the chambers from the plurality of chambers  135  are radially spaced and/or axially spaced along the interface  139 . In one or more exemplary embodiments, the spacing of chambers from the plurality of chambers  135  in the radial and axial directions forms a chamber array. In one or more exemplary embodiments, each chambers from the plurality of chambers  135  may be a variety of shapes, such as a spherical, a cone, a pyramid, a cube, a cylinder, etc. In one or more exemplary embodiments, the chambers from the plurality of chambers  135  may be spaced in a variety of arrays to form an integrally formed single-component pump-out plug  100 . A portion of the pump-out plug  100  is “weakened” along the shear zone  139  using the plurality of chambers  135 . In one or more exemplary embodiments, the density of the chambers  135  within the interface  139  may be uniform or gradient. In one or more exemplary embodiments, each of the chambers in the plurality of chambers  135  is of engineered size distribution and chamber density distribution. In one or more exemplary embodiments, the plurality of chambers  135  is pre-determined by numerical analysis and do not detract from mechanical strength performance of the pump-out plug  100  when the pump-out plug  100  is in an axially compressed state. However, the plurality of chambers  135  is pre-determined by numeral analysis and does weaken the pump-out plus  100  such that when the pump-out plug  100  is in an axially tensile state, the cap  130  will detach from the tubular  122 . In an exemplary embodiment, the body  100  is a fused body formed from a fused material and the chambers from the plurality of chambers  135  are un-fused areas. In an exemplary embodiment, the chambers from the plurality of chambers  135  contain an un-fused material (they are not completely hollow). In an exemplary embodiment, the shear strength of the plug  100  is dependent upon a sectional area of an internal chamber or the sum of the sectional areas of the plurality of chambers  135  along a cylindric section, or a portion of a cylindric section, within the stress zone, or along the interface  139 .  FIG. 4  illustrates a perspective view of a partial cut-out of the tool  95  when the tool  95  is a shear annular element, such as a shear ring or a shear sleeve  160 . The shear sleeve  160  is formed from an integrally formed, single-component body  165  that has an inner diameter  170  that at least partially defines an inner radial portion  175 ; outer diameter  180  that at least partially defines an outer radial portion  185 ; and an axial length  190  defined in an axial direction indicated by the numeral  195 A or an opposing axial direction indicated by the numeral  195 B in the  FIG. 4 . In an exemplary embodiment, a plurality of interior chambers  200  are formed within the body  165  at an interface  205  of the inner portion  175  and the outer portion  185 . In an exemplary embodiment, the interface  205  is a zone of the body  165  that is adjacent at least one internal chamber of the plurality of internal chambers  200 . In an exemplary the plurality of chambers  200  creates a stress concentration zone in the body  165  at the interface  205  when the shear sleeve  160  is subjected to one or more stresses. The stress concentration zone may extend along the length  190  or a portion of the length  190  of the shear sleeve  160 . In an exemplary embodiment, the interface  205  forms a geometry such as, for example a line, a tubular, a segment of a tubular, etc. 
       FIG. 5A  illustrates the shear sleeve  160  in a run-in or first configuration, in which the inner portion  175  is integrally formed to the outer portion  185 . In an exemplary embodiment, the shear sleeve  160  is concentrically disposed between an outer sleeve  210  and an inner sleeve  215 . The shear sleeve  160  may be coupled to each of the inner sleeve  215  and the outer sleeve  210  in a variety of ways, such as for example, by a friction fit, etc. In the first configuration, the sleeve  160  withstands a predetermined range of shear forces that are applied to the shear sleeve  160  in either the direction  195 B or direction  195 A when the inner sleeve  215  is urged to move relative to the outer sleeve  210 . As the body  165  forms both the radial portion  175  and the outer radial portion  185 , the shear plug  160  is a single component shear sleeve. 
       FIG. 5B  illustrates the shear sleeve  160  in an actuated or second configuration, in which the inner portion  175  is detached from the outer portion  185 . In an exemplary embodiments, and when a shear force is applied in the axial direction (i.e., the direction  195 B or direction  195 A), the inner radial portion  175  is separated from the outer radial portion  185  along the interface  205 . That is, when an axial force is applied to the shear sleeve  160  that results in a shear stress occurring in the interface  205  that exceeds the shear strength of the material forming the body  165 , then the inner portion  175  breaks away from the outer portion  185  to allow relative movement between the inner sleeve  215  and the outer sleeve  210 . In an exemplary embodiment, the sleeve  160  withstands bi-direction pressures until a predetermined shear pressure is exerted on the shear sleeve  160 . Thus, the shear sleeve  160  is a bi-directional shear sleeve. 
     Generally, the plurality of chambers  200  is substantially identical to the plurality of chambers  135 . The chambers from the plurality of chambers  200  are internal chambers, which are chambers that are spaced from an external surface  165   a  of the body  165  or are chambers that do not penetrate the external surface  165   a . In one or more exemplary embodiment, the chambers from the plurality of chambers  200  are radially spaced and/or axially spaced along the interface  205 . In one or more exemplary embodiments, the spacing of chambers from the plurality of chambers  200  in the radial and axial directions forms a chamber array. In one or more exemplary embodiments, the chambers from the plurality of chambers  200  may be spaced in a variety of arrays to form an integrally formed single-component shear sleeve  160 . A portion of the shear sleeve  160  is “weakened” along the interface  205  using the plurality of chambers  200 . In one or more exemplary embodiments, each of the chambers in the plurality of chambers  200  is of engineered size distribution and chamber density distribution. In an exemplary embodiment, the body  165  is a fused body formed from a fused material and the chambers from the plurality of chambers  200  are un-fused areas. In an exemplary embodiment, the chambers from the plurality of chambers  200  contain an un-fused material (they are not completely hollow). In an exemplary embodiment, the shear strength of the shear sleeve  160  is dependent upon a sectional area of an internal chamber or the sum of the sectional areas of the plurality of chambers  200  along the interface  165  or a portion of the interface  165 . 
       FIGS. 6A and 6B  illustrate sectional views of the shear sleeve  160  when a chamber from the plurality of chambers  200  extends along the length  190  of the sleeve  160 . In an exemplary embodiment, the portion of the body  165 , or webbing, within the zone  205  may be designed to have a specific cross-sectional area to cause the webbing to be sheared or fail in tensile at a specific load. The load to shear the webbing could be hydraulically or mechanically. Moreover, although the webbing is integrally formed with the inner radial portion  175  and the outer radial portion  185 , the webbing may be a different material than the material forming the inner radial portion  175  and the outer radial portion  185 . In fact, the webbing may be made out of a material that is “weaker” than the material of the inner radial portion  175  and the outer radial portion  185 . The webbing could be staggered across the sleeve  160  to evenly distribute the load for thin-wall parts. 
     In an alternate embodiment, the outer radial portion  185  is the outer sleeve  210  and the inner radial portion  175  is the inner sleeve  215 . 
       FIGS. 7A and 7B  illustrate sectional views of the tool  95  when the tool  95  is a shear pin  220 . The shear pin  220  is formed from an integrally formed body  225  that has an outer dimension  230  associated with a pin size. As shown, the shape of the cross-section of the pin  220  as shown in  FIG. 7B  forms a circle. However, the shape of the cross-section of the pin  220  may be any shape, such as for example a square, a hexagon or any other polygon, an oval, etc. In an exemplary embodiment, the integrally formed, single-component body  225  has a first end portion  235 ; a second opposing second end portion  240 ; and a length  242 . In an exemplary embodiment, a plurality of interior chambers  245  are formed within the body  225  at an interface  250  of the first end portion  235  and the second end portion  240 . In an exemplary embodiment, the interface  250  is a zone of the body  225  that is adjacent at least one internal chamber of the plurality of internal chambers  245 . In an exemplary embodiment, the interface  250  forms a cylindric section, or a portion of a cylindric section, within the shear pin  220 . For example, the interface  250  may form a plane that is perpendicular to a longitudinal axis of the shear pin  220 . In an exemplary the plurality of chambers  245  creates a stress concentration zone in the body  225  at the interface  250  when the shear pin  220  is subjected to one or more stresses. In an exemplary embodiment, the interface  250  and therefore the stress zone forms a geometry such as, for example a line, a plane, a cylinder, a section of a cylinder etc. 
       FIG. 8A  illustrates the shear pin  220  in a run-in or first configuration, in which the body  225  is integrally formed such that the first end portion  235  is integrally attached to the second end portion  240 . In an exemplary embodiment, the first end portion  235  of the shear pin  220  is coupled to the outer sleeve  210  and the second end portion  240  of the shear pin  220  is coupled to the inner sleeve  215 . The shear pin  220  may be coupled to each of the inner sleeve  215  and the outer sleeve  210  in a variety of ways, such as for example, by a friction fit, etc. In the first configuration, the pin  220  withstands a predetermined range of shear forces that are applied to the shear pin  220  in a direction that is generally perpendicular to a length  242  of the pin  220  (i.e., the direction  195 B or the direction  195 A), as when the inner sleeve  215  is urged to move relative to the outer sleeve  210 . 
       FIG. 8B  illustrates the shear pin  220  in an actuated or second configuration, in which the first end portion  235  is detached or sheared from the second end portion  240 . In an exemplary embodiment, and when a shear force is applied in the direction that is generally perpendicular to the length  242  of the pin  220  (i.e., the direction  195 B or the direction  195 A), the first end portion  235  is separated from the second end portion  240  along the interface  250 . That is, the first end portion  235  breaks away from the second end portion  240  along the interface  250  to allow relative movement between the inner sleeve  215  and the outer sleeve  210  when a shear force is applied to the pin  220  that exceeds the shear strength of the material of the body  225 . 
     Generally, the plurality of chambers  245  is substantially identical to the plurality of chambers  135 . The chambers from the plurality of chambers  245  are internal chambers, which are chambers that are spaced from an external surface  225   a  of the body  225  or are chambers that do not penetrate the external surface  225   a . In one or more exemplary embodiments, the chambers from the plurality of chambers  245  are radially spaced and/or axially spaced along the interface  250 . In one or more exemplary embodiments, the spacing of chambers from the plurality of chambers  245  in the radial and axial directions forms a chamber array. In one or more exemplary embodiments, the chambers from the plurality of chambers  245  may be spaced in a variety of arrays to form an integrally formed single-component shear pin  220 . A portion of the shear pin  220  is “weakened” along the interface  250  using the plurality of chambers  245 . In one or more exemplary embodiments, each of the chambers in the plurality of chambers  245  is of engineered size distribution and chamber density distribution. In an exemplary embodiment, the body  225  is a fused body formed from a fused material and the chambers from the plurality of chambers  245  are un-fused areas. In an exemplary embodiment, the chambers from the plurality of chambers  245  contain an un-fused material (they are not completely hollow). In an exemplary embodiment, the shear strength of the shear pin  220  is dependent upon a sectional area of an internal chamber or the sum of the sectional areas of the plurality of chambers  240  along a cylindric section, or a portion of a cylindric section, within the stress zone, or along the interface  250 . 
       FIG. 9A  is a perspective view of the tool  95  when the tool is a millable tool, such as a millable packer  260 .  FIGS. 9B and 9C  are sectional views of the millable packer  260 . Generally, the millable packer  260  includes a component, such as a metal component  265 . The metal component  265  may include an integrally formed, single-component body  270  forming a plurality of internal chambers  275 . The plurality of internal chambers  275  is formed within the body  270  to form a release-by-milling zone  280 . In an exemplary embodiment, the zone  280  forms a geometry, such as a line, a plane, an arc, a cylinder, a section of a cylinder, etc. In an exemplary embodiment, the plurality of chambers  275  creates a stress concentration zone that corresponds with the interface  280  in the body  270  such that when the millable packer  260  is milled and therefore subjected to stress (i.e., shear stress, compressive stress, or tensile stress), the body  270  breaks along the zone  280 . Thus, it is easy to mill out the millable tool. While the plurality of internal chambers  275  does not reduce or affect the performance of the millable packer  260 , it does result in weaker resistance during milling operations. Specifically, the compression strength of the component  265  is not changed, yet the speed of milling operations is increased and/or effort of milling operations is decreased. 
     Generally, the plurality of chambers  275  is substantially identical to the plurality of chambers  135 . The chambers from the plurality of chambers  275  are internal chambers, which are chambers that are spaced from an external surface  270   a  of the body  270  or are chambers that do not penetrate the external surface  270   a . In one or more exemplary embodiments, the chambers from the plurality of chambers  275  are radially spaced and/or axially spaced along the zone  280 . In one or more exemplary embodiments, the spacing of chambers from the plurality of chambers  275  in the radial and axial directions forms a chamber array. A portion of the body  270  is “weakened” along the zone  280  using the plurality of chambers  275 . In one or more exemplary embodiments, each of the chambers in the plurality of chambers  275  is of engineered size distribution and chamber density distribution. In an exemplary embodiment, the body  270  is a fused body formed from a fused material and the chambers from the plurality of chambers  275  are un-fused areas. In an exemplary embodiment, the chambers from the plurality of chambers  275  contain an un-fused material (they are not completely hollow). In an exemplary embodiment, the shear strength of the component is dependent upon a sectional area of an internal chamber or the sum of the sectional areas of the plurality of chambers  275  along the zone  280  or a portion of the zone  280 . 
     Exemplary embodiments of the present disclosure may be altered in a variety of ways. For example, the component  265  may form any number of tools, such as for example, a millable plug, a millable valve, etc. Additionally, the tool  95  is not limited to the plug  100 , the sleeve  160 , the pin  220 , and the millable tool  260 , but can be any tool or tool component that is designed to have a first configuration in which relative movement between two components is prevented and a second configuration in which relative movement between the two components is desired. Additionally, when in the first configuration the tool  95 , and considering the body is integrally formed, the tool  95  forms a pressure seal. The reduction of components simplifies manufacture of the tool  95  and reduces cost associated with the manufacture of the tool  95 . Moreover, the reduction of components simplifies, reduces, or eliminates assembly of the tool  95  or of a tool that uses the tool  95  in the field, which may reduce or eliminate assembly errors made in the field. 
     In an exemplary embodiment and as shown in  FIG. 10 , a down-hole tool printing system  350  includes one or more computers  355  and a printer  360  that are operably coupled together, and in communication via a network  365 . In one or more exemplary embodiments, the tool  95  may be manufactured using the downhole tool printing system  350 . In one or more exemplary embodiments, the one or more computers  355  include a computer processor  370  and a computer readable medium  375  operably coupled thereto. In one or more exemplary embodiments, the computer processor  370  includes one or more processors. Instructions accessible to, and executable by, the computer processor  370  are stored on the computer readable medium  375 . A database  380  is also stored in the computer readable medium  375 . In one or more exemplary embodiments, the computer  355  also includes an input device  385  and an output device  390 . In one or more exemplary embodiments, web browser software is stored in the computer readable medium  375 . In one or more exemplary embodiments, three dimensional modeling software is stored in the computer readable medium. In one or more exemplary embodiments, software that includes advanced numerical methods for topology optimization, which assists in determining optimum chamber shape, chamber size distribution, and chamber density distribution or other topological features in the tool  95 , is stored in the computer readable medium. In one or more exemplary embodiments, software involving finite element analysis and topology optimization is stored in the computer readable medium  375 . In one or more exemplary embodiments, any one or more constraints are entered in the input device  385  such that the software aids in the design on a tool  95  in which specific portions of the body of the tool  95  remain solid (i.e., no chambers are formed). In one or more exemplary embodiments, the input device  385  is a keyboard, mouse, or other device coupled to the computer  355  that sends instructions to the computer  355 . In one or more exemplary embodiments, the input device  385  and the output device  390  include a graphical display, which, in several exemplary embodiments, is in the form of, or includes, one or more digital displays, one or more liquid crystal displays, one or more cathode ray tube monitors, and/or any combination thereof. In one or more exemplary embodiments, the output device  390  includes a graphical display, a printer, a plotter, and/or any combination thereof. In one or more exemplary embodiments, the input device  385  is the output device  390 , and the output device  390  is the input device  385 . In several exemplary embodiments, the computer  355  is a thin client. In several exemplary embodiments, the computer  355  is a thick client. In several exemplary embodiments, the computer  355  functions as both a thin client and a thick client. In several exemplary embodiments, the computer  355  is, or includes, a telephone, a personal computer, a personal digital assistant, a cellular telephone, other types of telecommunications devices, other types of computing devices, and/or any combination thereof. In one or more exemplary embodiments, the computer  355  is capable of running or executing an application. In one or more exemplary embodiments, the application is an application server, which in several exemplary embodiments includes and/or executes one or more web-based programs, Intranet-based programs, and/or any combination thereof. In one or more exemplary embodiments, the application includes a computer program including a plurality of instructions, data, and/or any combination thereof. In one or more exemplary embodiments, the application written in, for example, HyperText Markup Language (HTML), Cascading Style Sheets (CSS), JavaScript, Extensible Markup Language (XML), asynchronous JavaScript and XML (Ajax), and/or any combination thereof. 
     In one or more exemplary embodiments, the printer  360  is a three-dimensional printer. In one or more exemplary embodiments, the printer  360  includes a layer deposition mechanism for depositing material in successive adjacent layers; and a bonding mechanism for selectively bonding one or more materials deposited in each layer. In one or more exemplary embodiments, the printer  360  is arranged to form a unitary printed body by depositing and selectively bonding a plurality of layers of material one on top of the other. In one or more exemplary embodiments, the printer  360  is arranged to deposit and selectively bond two or more different materials in each layer, and wherein the bonding mechanism includes a first device for bonding a first material in each layer and a second device, different from the first device, for bonding a second material in each layer. In one or more exemplary embodiments, the first device is an ink jet printer for selectively applying a solvent, activator or adhesive onto a deposited layer of material. In one or more exemplary embodiments, the second device is a laser for selectively sintering material in a deposited layer of material. In one or more exemplary embodiments, the layer deposition means includes a device for selectively depositing at least the first and second materials in each layer. In one or more exemplary embodiments, any one of the two or more different materials may be ABS plastic, PLA, polyamide, glass filled polyamide, stereolithography materials, silver, titanium, steel, wax, photopolymers, polycarbonate, and a variety of other materials. In one or more exemplary embodiments, the printer  360  may involve fused deposition modeling, selective laser sintering, and/or multi-jet modeling. In operation, the computer processor  370  executes a plurality of instructions stored on the computer readable medium  375 . As a result, the computer  355  communicates with the printer  360 , causing the printer  360  to manufacture the tool  95  or at least a portion thereof. In one or more exemplary embodiments, manufacturing the tool  95  using the system  350  results in an integrally formed tool  95 . 
     In one or more exemplary embodiments, as illustrated in  FIG. 11  with continuing reference to  FIGS. 1, 2, 3A, 3B, 4, 5A, 5B, 6A, 6B, 7A, 7B   8 A,  8 B,  9 A,  9 B,  9 C, and  10 , an illustrative computing device  1000  for implementing one or more embodiments of one or more of the above-described networks, elements, methods and/or steps, and/or any combination thereof, is depicted. The computing device  1000  includes a processor  1000   a , an input device  1000   b , a storage device  1000   c , a video controller  1000   d , a system memory  1000   e , a display  1000   f , and a communication device  1000   g , all of which are interconnected by one or more buses  1000   h . In several exemplary embodiments, the storage device  1000   c  may include a floppy drive, hard drive, CD-ROM, optical drive, any other form of storage device and/or any combination thereof. In several exemplary embodiments, the storage device  1000   c  may include, and/or be capable of receiving, a floppy disk, CD-ROM, DVD-ROM, or any other form of computer readable medium that may contain executable instructions. In one or more exemplary embodiments, the computer readable medium is a non-transitory tangible media. In several exemplary embodiments, the communication device  1000   g  may include a modem, network card, or any other device to enable the computing device  1000  to communicate with other computing devices. In several exemplary embodiments, any computing device represents a plurality of interconnected (whether by intranet or Internet) computer systems, including without limitation, personal computers, mainframes, PDAs, smartphones and cell phones. 
     In several exemplary embodiments, the one or more computers  355 , the printer  360 , and/or one or more components thereof, are, or at least include, the computing device  1000  and/or components thereof, and/or one or more computing devices that are substantially similar to the computing device  1000  and/or components thereof. In several exemplary embodiments, one or more of the above-described components of one or more of the computing device  1000 , one or more computers  355 , and the printer  360  and/or one or more components thereof, include respective pluralities of same components. 
     In several exemplary embodiments, a computer system typically includes at least hardware capable of executing machine readable instructions, as well as the software for executing acts (typically machine-readable instructions) that produce a desired result. In several exemplary embodiments, a computer system may include hybrids of hardware and software, as well as computer sub-systems. 
     In several exemplary embodiments, hardware generally includes at least processor-capable platforms, such as client-machines (also known as personal computers or servers), and hand-held processing devices (such as smart phones, tablet computers, personal digital assistants (PDAs), or personal computing devices (PCDs), for example). In several exemplary embodiments, hardware may include any physical device that is capable of storing machine-readable instructions, such as memory or other data storage devices. In several exemplary embodiments, other forms of hardware include hardware sub-systems, including transfer devices such as modems, modem cards, ports, and port cards, for example. 
     In several exemplary embodiments, software includes any machine code stored in any memory medium, such as RAM or ROM, and machine code stored on other devices (such as floppy disks, flash memory, or a CD ROM, for example). In several exemplary embodiments, software may include source or object code. In several exemplary embodiments, software encompasses any set of instructions capable of being executed on a computing device such as, for example, on a client machine or server. 
     In several exemplary embodiments, combinations of software and hardware could also be used for providing enhanced functionality and performance for certain embodiments of the present disclosure. In one or more exemplary embodiments, software functions may be directly manufactured into a silicon chip. Accordingly, it should be understood that combinations of hardware and software are also included within the definition of a computer system and are thus envisioned by the present disclosure as possible equivalent structures and equivalent methods. 
     In several exemplary embodiments, computer readable mediums include, for example, passive data storage, such as a random access memory (RAM) as well as semi-permanent data storage such as a compact disk read only memory (CD-ROM). One or more exemplary embodiments of the present disclosure may be embodied in the RAM of a computer to transform a standard computer into a new specific computing machine. In several exemplary embodiments, data structures are defined organizations of data that may enable an embodiment of the present disclosure. In one or more exemplary embodiments, a data structure may provide an organization of data, or an organization of executable code. 
     In several exemplary embodiments, the network  365 , and/or one or more portions thereof, may be designed to work on any specific architecture. In one or more exemplary embodiments, one or more portions of the network  365  may be executed on a single computer, local area networks, client-server networks, wide area networks, internets, hand-held and other portable and wireless devices and networks. 
     In several exemplary embodiments, a database may be any standard or proprietary database software, such as Oracle, Microsoft Access, SyBase, or DBase II, for example. In several exemplary embodiments, the database may have fields, records, data, and other database elements that may be associated through database specific software. In several exemplary embodiments, data may be mapped. In several exemplary embodiments, mapping is the process of associating one data entry with another data entry. In one or more exemplary embodiments, the data contained in the location of a character file can be mapped to a field in a second table. In several exemplary embodiments, the physical location of the database is not limiting, and the database may be distributed. In one or more exemplary embodiments, the database may exist remotely from the server, and run on a separate platform. In one or more exemplary embodiments, the database may be accessible across the Internet. In several exemplary embodiments, more than one database may be implemented. 
     In several exemplary embodiments, a computer program, such as a plurality of instructions stored on a computer readable medium, such as the computer readable medium  375 , the system memory  1000   e , and/or any combination thereof, may be executed by a processor to cause the processor to carry out or implement in whole or in part the operation of the system  350 , and/or any combination thereof. In several exemplary embodiments, such a processor may include one or more of the computer processor  370 , the processor  1000   a , and/or any combination thereof. In several exemplary embodiments, such a processor may execute the plurality of instructions in connection with a virtual computer system. 
     In several exemplary embodiments, a plurality of instructions stored on a computer readable medium may be executed by one or more processors to cause the one or more processors to carry out or implement in whole or in part the above-described operation of each of the above-described exemplary embodiments of the system, the method, and/or any combination thereof. In several exemplary embodiments, such a processor may include one or more of the microprocessor  1000   a , any processor(s) that are part of the components of the system, and/or any combination thereof, and such a computer readable medium may be distributed among one or more components of the system. In several exemplary embodiments, such a processor may execute the plurality of instructions in connection with a virtual computer system. In several exemplary embodiments, such a plurality of instructions may communicate directly with the one or more processors, and/or may interact with one or more operating systems, middleware, firmware, other applications, and/or any combination thereof, to cause the one or more processors to execute the instructions. 
     In one or more exemplary embodiments, the instructions may be generated, using in part, advanced numerical method for topology optimization to determine optimum chamber shape, chamber size and distribution, and chamber density distribution for the plurality of chambers  135 ,  200 ,  245 , and/or  275 , or other topological features. 
     During operation of the system  350 , the computer processor  370  executes the plurality of instructions that causes the manufacture of the tool  95  using additive manufacturing. Thus, the tool  95  is at least partially manufactured using an additive manufacturing process. Manufacturing the tool  95  via machining forged billet stock or using multi-axis milling processes often limits the geometries and design of the tool  95 . Thus, with additive manufacturing, complex geometries—such as internal chambers  135 ,  200 ,  245 , and/or  275 —are achieved or allowed, which results in the creation of stress concentration zones within the tool  95 . In one or more exemplary embodiments, the use of three-dimensional, or additive, manufacturing to manufacture downhole equipment, such as the tool  95 , will allow increased flexibility in the strategic placement of material to retain strength in one direction but reduce strength, or weaken the tool in another direction. 
     Thus, a subsurface tool adapted to extend within a wellbore has been described. Embodiments of the tool may generally include an integrally formed single-component body that defines an external surface; and an internal chamber isolated from the external surface, wherein, when the tool is subjected to one or more stresses, a stress concentration is created within a stress zone of the single-component body, the stress zone being adjacent the internal chamber. 
     Additionally, an apparatus has been described. Embodiments of the apparatus may generally include a non-transitory computer readable medium; and a plurality of instructions stored on the non-transitory computer readable medium and executable by one or more processors, the plurality of instructions including instructions that cause the manufacture of a subsurface tool adapted to extend within a wellbore, the tool includes an integrally formed single-component body that defines: an external surface; and an internal chamber isolated from the external surface; when the tool is subjected to one or more stresses, a stress concentration is created within a stress zone of the single-component body, the stress zone being adjacent the internal chamber. Any of the foregoing embodiments may include any one of the following elements, alone or in combination with each other:
         The tool is a millable packer; and the stress zone extends within a release-by-milling zone.   The tool is a bi-directional pressure plug having a first configuration in which the body of the plug integrally forms a tubular portion that defines an interior passage; and a plug portion connected to the tubular to form an interface therebetween, the plug portion extending across the interior passage; wherein the stress zone extends within the body at the interface; and a second configuration in which the plug portion is not connected to the tubular at the interface.   The tool is a bi-direction pressure plug having a second configuration in which the plug portion is separated from the tubular portion.   The bi-directional pressure plug is a single-component, bi-directional pressure plug.   The subsurface tool is a shear annular element having a first configuration in which the body of the shear annular element defines an outer diameter that at least partially defines an outer radial portion; an inner diameter that at least partially defines an inner radial portion; and an axial length, wherein a stress zone extends between the inner radial portion and the outer radial portion along at least a portion of the axial length of the body.   The shear annular element has a second configuration in which the inner radial portion is sheared from the outer radial portion along the stress zone.   The shear annular element is a single-component shear sleeve.   The tool is a shear pin having a first configuration in which the body forms a first end portion; and a second opposing end portion, with the stress zone extending between the first end portion and the second end portion; and a second configuration in which the first end portion is sheared from the second end portion.   The shear strength of the shear pin is dependent upon a sectional area of the internal chamber along a portion of a cylindric section within the stress zone.   The tool is at least partially manufactured using an additive manufacturing process.       

     In several exemplary embodiments, while different steps, processes, and procedures are described as appearing as distinct acts, one or more of the steps, one or more of the processes, and/or one or more of the procedures may also be performed in different orders, simultaneously and/or sequentially. In several exemplary embodiments, the steps, processes and/or procedures may be merged into one or more steps, processes and/or procedures. In several exemplary embodiments, one or more of the operational steps in each embodiment may be omitted. Moreover, in some instances, some features of the present disclosure may be employed without a corresponding use of the other features. Although various embodiments and methods have been shown and described, the disclosure is not limited to such embodiments and methods and will be understood to include all modifications and variations as would be apparent to one skilled in the art. Therefore, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Accordingly, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the disclosure as defined by the appended claims. The foregoing description and figures are not drawn to scale, but rather are illustrated to describe various embodiments of the present disclosure in simplistic form.