# US 11,078,729 B2 · System and method for manufacturing downhole tool components

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 11,078,729 B2
- Document ID: US11078729B2
- Status: Granted
- Kind: B2
- Application number: 16/198,065
- Filed: 2018-11-21
- Published: 2019-03-28
- Granted: 2021-08-03
- Earliest claimed: 2018-11-21
- Assignees: Halliburton Energy Services, Inc.
- Applicants: Halliburton Energy Services, Inc.
- Inventors: Alston Jun Ngai Wong; Jia Ming Kew; Doren Hui Ping Ho; Guan Yee Chan
- Web page: https://patentgrep.com/patent/US11078729B2

## CPC

- E21B 17/00: Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; {Cables;} Casings; Tubings
- B22F 3/105: by using electric current {other than for infrared radiant energy}, laser radiation or plasma (B22F3/11 takes precedence){; by ultrasonic bonding (B22F3/115 takes precedence)}
- B22F 5/00: Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F 7/062: {involving the connection or repairing of preformed parts}
- B23K 15/0006: {specially adapted for particular articles or work}
- B23K 15/0053: {Seam welding}
- B22F 2005/001: {Cutting tools, earth boring or grinding tool other than table ware}
- E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM

## Abstract

A method is provided for manufacturing a segment of a drill string, such as a tubular tool, from a plurality of layers. The method includes arranging a plurality of layers based on a selected length of the segment. Each of the plurality of layers includes an aperture that is received over an alignment feature that restricts movement of the plurality of layers to two or fewer degrees of freedom. A joining process is performed to join the plurality of layers, which may include at least one replacement layer.

## Claims

### Claim 1

A system for assembling a segment of a drill string, the system comprising:
a plurality of unfused physical layers including an aperture formed therein, the plurality of unfused physical layers manufactured based on a plurality of planned layers, the plurality of planned layers determined by slicing a virtual three-dimensional tubular structure into the plurality of planned layers;
an alignment feature having the plurality of unfused physical layers inserted over the alignment feature to align the aperture formed therein from the plurality of unfused physical layers, and
wherein the plurality of unfused physical layers are fused to form the segment, the aperture of each of the plurality of unfused physical layers together forming a common bore.

### Claim 2 (depends on 1)

The system of claim 1, wherein the plurality of unfused physical layers are fused via electron beam welding.

### Claim 3 (depends on 1)

The system of claim 1, wherein the plurality of unfused physical layers are arranged in a preselected order over the alignment feature.

### Claim 4 (depends on 1)

The system of claim 1, wherein the alignment feature is spiral shaped.

### Claim 5 (depends on 1)

The system of claim 1, wherein the alignment feature maintains design tolerances for the segment.

### Claim 6 (depends on 1)

The system of claim 1, wherein the alignment feature comprises parallel rods and each of the plurality of unfused physical layers includes two or more apertures formed therein to receive the parallel rods.

### Claim 7 (depends on 6)

The system of claim 6, wherein the parallel rods comprise a large rod and a small rod, the large rod having a larger diameter than the small rod.

### Claim 8 (depends on 7)

The system of claim 7, further comprising fitting an insert over at least one of the large rod or the small rod before arranging the plurality of unfused physical layers over the alignment feature.