US Patent 10358890 Wellbore seals with complex features through additive manufacturing

A wellbore sealing device having an elastomeric element with complex features and associated additive manufacturing method is disclosed. The complex features can include voids such as isolated voids and undercut-like voids that cannot be reasonably produced using existing molding techniques (e.g., due physically impossible mold shapes or cost-prohibitive mold requirements). These complex features can alleviate stress and increase radial expansion of the elastomeric element in response to axial compression of the elastomeric element. Such elastomeric elements with complex features can be additively manufactured (e.g., through three dimensional printing). In some cases, the elastomeric elements can be additively manufactured directly on a tool, such as on an end plate or mandrel of a wellbore sealing device.