This study investigates the mechanical behavior of Nylon 12 Carbon Fiber specimens manufactured through fused filament fabrication (FFF) for potential integration into light water well drilling rigs. Fifteen tensile test samples were 3D-printed on a MakerBot Method X printer in three orientations: horizontal, vertical, and lateral. Each specimen was printed with a soluble SR-30 support material, which was subsequently dissolved in an SCA 1200-HT wash station using heated alkaline solution. Following support removal, all samples underwent thermal annealing at 80 °C for 5 h in the printer’s controlled chamber to eliminate residual moisture and improve structural integrity. The annealed specimens were subjected to uniaxial tensile testing using an Instron 8875 electrohydraulic machine, with strain measured by digital image correlation (DIC) on a speckle-patterned gauge section. Key mechanical properties, including Young’s modulus, Poisson’s ratio, yield strength, and ultimate tensile strength, were determined. Finally, a finite element analysis (FEA) was performed using MSC Visual Nastran for Windows to simulate the tensile loading conditions and assess internal stress distributions for each print orientation. The combined experimental and numerical results confirm the feasibility of using additively manufactured parts in demanding engineering applications.

This study investigates the dynamic behavior and structural optimization of hydraulic water well drilling rig masts through a comparative finite element analysis (FEA) of metallic and composite configurations. The reference model, manufactured from structural steel (S355J2/E315), was compared with two optimized lightweight alternatives made of carbon fiber reinforced polymer (CFRP) and glass fiber reinforced polymer (GFRP) laminates. Simulations were performed in MSC Visual Nastran using identical geometric and loading conditions, including the critical dynamic event of drill string pull-out. The results demonstrate that substituting steel with composite materials significantly decreases the overall mass by up to 55%, while increasing the first natural frequency by 20–25% and reducing dynamic stress amplification by approximately 15–20%. Furthermore, the maximum tip displacement of the mast was reduced by 35–45% for the composite variants, indicating improved stiffness and vibration damping capability. These findings confirm that polymer composite structures offer superior dynamic performance, lower inertial loads, and enhanced operational safety, providing a viable route for next-generation lightweight drilling rig designs integrating advanced macromolecular materials.

This paper presents a code-based static verification of the FA125 hydraulic drilling rig mast under its governing design load combination. Unlike the previously published dynamic investigation of the same platform, the present work establishes the baseline static load path, identifies the governing structural members, evaluates the local stress state in the mast-to-support connection plates, and computes the effective safety coefficients. The mixed finite element model integrates the lattice mast, the support frame, and the base assembly, utilizing beam elements for the slender load-bearing members and shell elements for the localized plate-type connection regions. The governing load combination encompasses structural self-weight, maximum hook load (14.90 kN), and the reactive torque transmitted by the drilling head (0.50 kNm). The maximum mast-top displacement was limited to 4.75 mm. The critical beam elements were located within the lateral base-support region, developing peak compressive and tensile stresses of 70.08 MPa and 69.21 MPa, respectively. The highest localized shell-level von Mises stress (23.62 MPa) was concentrated within the mast-to-support interface connection plates. The results mathematically confirm that the existing FA125 steel structure satisfies the active design criteria, providing a distinct static reference map required for subsequent structural optimization, lightweighting, and selective material substitution.