MOLDS AND METHODS OF FORMING MOLDS ASSOCIATED WITH MANUFACTURE OF ROTARY DRILL BITS AND OTHER DOWNHOLE TOOLS
First Claim
1. A method of forming a mold operable to fabricate at least one component of a well drilling tool comprising:
- (a) using a three dimensional (3D) printer to deposit a thin layer of powder;
(b) using the 3D printer to apply binder material to the thin layer of powder having a configuration and dimensions based on three dimensional (3D) design data associated with the well drilling tool; and
repeating steps (a) and (b) to produce the mold with a mold cavity having a configuration and dimensions based on the 3D design data for the associated well drilling tool.
1 Assignment
0 Petitions
Accused Products
Abstract
Three dimensional printing equipment and techniques may be used in combination with three dimensional design data associated with well drilling equipment and well completion equipment to form molds associated with manufacture of such equipment. For example, such molds may be used to form a bit body or other components associated with a rotary drill bit. For some applications composite or matrix materials may be placed in the mold to form a matrix bit body. Heat transfer characteristics of the mold may be optimized for heating and/or cooling of the matrix materials to provide optimum fracture resistant (toughness) and optimum erosion, abrasion and/or wear resistance for portions of the bit body. Such molds may also be used to form steel bit bodies associated with fixed cutter rotary drill bits and other components associated with a wide variety of well drilling equipment and well completion equipment.
103 Citations
45 Claims
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1. A method of forming a mold operable to fabricate at least one component of a well drilling tool comprising:
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(a) using a three dimensional (3D) printer to deposit a thin layer of powder;
(b) using the 3D printer to apply binder material to the thin layer of powder having a configuration and dimensions based on three dimensional (3D) design data associated with the well drilling tool; and
repeating steps (a) and (b) to produce the mold with a mold cavity having a configuration and dimensions based on the 3D design data for the associated well drilling tool. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 41)
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11. A method of forming a mold operable to fabricate at least one component of a rotary drill bit comprising:
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(a) using a three dimensional (3D) printer to deposit a thin layer of powder;
(b) using the 3D printer to apply binder material to the thin layer of powder corresponding with a configuration and dimensions based on three dimensional (3D) design data for the rotary drill bit; and
repeating steps (a) and (b) to produce a mold having a mold cavity with a configuration and dimensions based on the 3D design data associated with the rotary drill bit. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 42)
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22. A method of forming a bit head for a matrix bit body comprising:
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(a) forming a first powder from at least a first infiltration material with heat transfer characteristics and dimensional stability characteristics in temperature ranges associated the matrix bit body;
(b) using a three dimensional (3D) printer to deposit a thin layer of the first powder;
(c) using the 3D printer to apply a binder material to the thin layer of the first powder with a configuration and dimensions corresponding to three dimensional (3D) design data associated with the bit head; and
repeating steps (b) and (c) to produce the bit head with a configuration and dimensions based on the 3D design data for the matrix bit body. - View Dependent Claims (23, 24, 25, 26, 43)
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27. A method of forming a mold operable to fabricate at least one component of a steel bit body for a fixed cutter drill bit comprising:
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(a) using a three dimensional (3D) printer to deposit a thin layer of powder;
(b) using the 3D printer to apply binder material to the thin layer of powder having a configuration and dimensions based on the three dimensional (3D) design data associated with the at least one component of the steel bit body; and
repeating steps (a) and (b) to produce the mold with a mold cavity having a configuration and dimensions corresponding with the 3D design data for the associated at least one component. - View Dependent Claims (28, 29, 30, 31)
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32. A method of forming a mold operable to fabricate at least one component of a well completion tool comprising:
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(a) using a three dimensional (3D) printer to deposit a thin layer of powder;
(b) using the 3D printer to apply binder material to the thin layer of powder having a configuration and dimensions derived from three dimensional (3D) design data associated with the well completion tool; and
repeating steps (a) and (b) to produce a mold having a mold cavity with a configuration and dimensions based on the 3D design data for the associated well completion tool. - View Dependent Claims (33, 34, 35, 36, 37, 38, 39, 40, 44)
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45. A mold operable to fabricate a bit head for a bit body comprising:
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a mold cavity extending between a first open end of the mold to a second closed end of the mold;
a plurality of displacements disposed within the mold cavity;
each displacement having a complex, arcuate configuration corresponding with a desired configuration for a respective fluid flow path disposed on exterior portions of the bit head;
a plurality of negative blade profiles disposed within the mold cavity between associated displacements;
each negative blade profile having a complex, arcuate configuration corresponding with a desired configuration for a respective blade disposed on exterior portions of the bit head;
a plurality of fluid flow channels disposed on exterior portions of the mold with each fluid flow channel located generally proximate one of the displacements disposed within the mold cavity; and
each fluid flow channel disposed on exterior portions of the mold having an arcuate configuration.
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Specification