The Challenge

SQP Engineering, a Western Australian supplier of precision-machined products for the mining, oil, and gas sectors, was established in 2006. With a team of 10, they boast an extensive client list including industry giants like BHP and Woodside. Notably, SQP was the first in Western Australia to acquire an FX20 printer.

One of SQP’s clients, Strada Percussion Drilling Systems, faced a persistent issue in hard-rock drilling: accurately measuring the wear of drill bits.

Taras Olijnyk, Strada’s Chief Technology Officer, explains, “Drilling deep wells in hard rock requires regular bit changes due to wear. After use, drill bits are measured to assess their wear and then replaced with smaller bits, making the well progressively smaller with each change.”

Traditionally, this measurement involved using a series of steel or aluminum rings, ranging from 450mm (~17.5 in) to 250mm (~10 in) in 3mm increments. These rings were placed over the bit to estimate wear. However, this method was inaccurate, prone to operator error, and did not account for asymmetrical bits. These issues increased the risk of accidentally using an oversized replacement bit, which could cause the drill string to become stuck.

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The Solution

To address this longstanding problem, Olijnyk designed a precision caliper gauge specifically for additive manufacturing.

This additively manufactured gauge measures from three points instead of two, providing a more accurate average of the true size. It covers a range of 250mm to 450mm drill bits, effectively replacing numerous steel rings with a single part.

The printed tool is more portable, durable, and ergonomic than the metal rings. “It’s lighter and can be held in one hand. It’s cheap to air freight and can even be carried in your hand luggage. It’s rust and corrosion-proof and definitely user-friendly,” Olijnyk noted.

“We were able to decrease cost by 30% by printing the tool and cut lead time from 2 weeks to 2 days. Overall, production time was reduced by a factor of seven, eliminating machining time altogether,” said Taras.

Thanks to SQP’s FX20, Strada Percussion Drilling Systems built a superior tool while saving both money and time.

“What is awesome about 3D printing is that no detailed drawing is required. A part can be designed and modeled one day, printed overnight, and assembled and tested the next day. It’s been invaluable,” said Taras Olijnyk, CTO, Strada Percussion Drilling Systems Australia.

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Advantages

- **Higher Tool Performance:** Eliminates human error in measurement.
- **Automated Tool Development:** Saves machinists time.
- **Increased Durability and Portability:** More ergonomic and easier to handle.
- **Reduced Tooling Costs and Lead Time:** Significant cost savings and quicker production turnaround.

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