Design and analysis for tools that have to work the first time.
JL Consulting is a Houston technical consulting firm. We support drilling-tool companies and manufacturers with mechanical design, analysis and simulation, root-cause investigations, heat-treat and machining support, and quality-system and technical-training support.
WHO WE ARE
JL Consulting's team brings 18 years of experience, from NASA Mission Control to oilfield tools, heat treating and manufacturing.
We bring that background to every project: clear requirements, careful analysis, drawings a machine shop can build from, and plain-language reports you can act on.
We work by the hour on single questions, by the project on full design and analysis packages, quality-system work and training, or on retainer for ongoing support.
What we do
Mechanical design, analysis and failure investigation support for drilling tools and precision manufacturing.
Mechanical & Downhole Tool Design
3D models and production-ready 2D drawings for mud-motor, bearing-section and drill-string components. Designed with manufacturing and field maintenance in mind.
Analysis & Simulation Support
Finite element analysis (SOLIDWORKS Simulation), connection strength and make-up calculations, bearing load ratings and fatigue assessments, delivered as documented reports.
Failure Analysis & Reliability
Root-cause investigations, FMEA and design reviews that explain why a part failed and what to change in design, material, manufacturing or operating limits.
Reverse Engineering
Legacy or undocumented parts recreated as 3D models and 2D manufacturing drawings from physical samples and measurements, with material and processing requirements where needed.
Materials, Heat Treat & Manufacturing Support
Material specifications, heat-treat requirements, vendor RFQs, machining estimates and shop drawing support, from a team that has managed a commercial heat-treat operation.
Quality Systems & Technical Training
Help building and implementing quality programs, procedures and document control, plus technical training and procedure writing for your team.
18 years of aerospace, oil & gas and manufacturing experience
NASA Mission Control: ISS flight control and Space Shuttle in-flight maintenance experience.
Design → Analysis → Shop floor: design, heat-treat and machining experience under one roof.
JL Consulting Team
Aerospace-trained team with hands-on experience in downhole tools, heat treating and precision manufacturing.
Selected work
Anonymized examples from recent projects.
Steel flex shaft: design, FEA and fatigue assessment
2026
Problem: A drilling-tool company needed a new steel flex shaft and matching extension housing for a mud motor, with confidence that it would survive downhole loads.
Approach: Produced the shaft and extension-housing drawings. Ran SOLIDWORKS static simulations for lateral (power-section eccentricity) and vertical load cases, combining stall torque, operating temperature, gravity and rotation. Compared the cases to identify the governing one, and added a fatigue-life assessment with documented assumptions and sensitivities. Wrote a supporting material specification for the high-strength alloy steel.
Result: A Rev A drawing package and a full simulation report with factor-of-safety and fatigue conclusions, ready for quoting and manufacture.
Flow diverter-to-mandrel connection assessment
2026
Problem: After a flow-diverter box failure on a 7" tool, a drilling-services company needed to know whether the connection design was adequate.
Approach: Analyzed the flow diverter-to-mandrel connection, including connection strength across a range of outer and inner diameters, and documented the findings.
Result: A written analysis report with recommendations for next steps, delivered on an hourly engagement.
Stator connection interference investigation
2026
Problem: A stator connection was showing interference and scarring at make-up.
Approach: Reviewed the connection drawings and inspection data dimension by dimension and traced the problem to the pin-nose geometry as drawn.
Result: Confirmed the connection is sound when manufactured correctly, and recommended a modification to the pin nose (with follow-up testing) to remove the interference.
Mandrel catch retrofit
2026
Problem: At an operator's request, a drilling-tool company wanted to eliminate a threaded feature on a 6-3/4" motor mandrel.
Approach: Designed a split-ring mandrel catch with new retainer rings.
Result: Existing mandrels can be reworked to the new design rather than scrapped.
Have a part, a failure or a design question?
Send us drawings, photos or a short description, and we'll tell you how we can help and what it will take.