Selected Work
Anonymized examples of recent design, analysis, failure investigation and reverse engineering projects for drilling-tool companies and manufacturers.
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.
Mud-motor design review
2026
Problem: An oilfield services company wanted an independent review of a 6-5/8" mud-motor design.
Approach: Analyzed the flow diverter-to-mandrel connection, evaluated lower radial bearing length, and assessed whether the flow diverter could be extended.
Result: Design recommendations delivered in a short, fixed 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.
Reverse engineering of legacy parts
2025–2026
Problem: Several manufacturers needed drawings for parts that had no usable documentation, including a rod end and bushing, an antenna component and other legacy parts.
Approach:
- Built 3D models and 2D manufacturing drawings from the physical parts.
- For one client, ran a comparative study of the existing drawings, a prior report and the physical part.
Result: Buildable drawing packages and a documented comparison report.
Drawing packages and connection calculations for mud-motor product lines
2025–2026
Problem: A drilling-motor company needed drawings and calculations for multiple tool sizes.
Approach:
- Prepared and revised drawings for bearing-assembly and drive-line components.
- Provided connection strength and make-up calculations.
- Analyzed bearing static and dynamic load ratings across several motor sizes.
Result: Released drawings and calculation records supporting manufacturing and field use.
Background experience
- Heat-treat department commissioning: our team took a machine shop's new heat-treat department from equipment sourcing through commissioning and procedures.
- Downhole tool sustaining work: our team led mud-motor reliability improvements through design changes, more thorough failure investigations and metrics-driven corrective action.
- ISS and Space Shuttle operations: our leadership wrote and validated on-orbit maintenance procedures and resolved hardware anomalies in real time in NASA Mission Control. This included serving as lead in-flight maintenance officer for the final Space Shuttle flight.