Technology Breakthrough: Novel Sensors Enable World's First At-Bit Formation Imaging Tool

Abstract At-Bit Imaging (ABI) technology introduces a novel approach to subsurface characterization by integrating imaging sensors directly into the cutting structure of a polycrystalline diamond compact (PDC) drill bit. This new and potentially game-changing measurement for formation imaging enables direct acquisition of high-quality images at the bit, independent of fluid properties, and scalable across hole sizes—offering new possibilities for real-time geological interpretation while drilling. The imaging system was developed from scratch, with innovative measurement principles and is based on an ultra-compact, modular sensor design capable of generating 360-degree high-resolution images of the formation. These images are derived by mapping formation-interacting sensor data to the bit’s azimuthal and depth position, enabling characterization of bedding, dip, texture and structural events observed in formation during the drilling process. The images can be readily incorporated into established interpretation workflows alongside logging-while-drilling (LWD) and wireline data. The drill bit serves as the integration platform for imaging sensors, requiring careful engineering to maintain both sensor functionality and the bit’s primary role in efficient formation drilling. Finite element analysis (FEA) was employed to evaluate drilling dynamics and guide the bit design, ensuring optimal sensor placement without compromising mechanical performance. The resulting design preserves directional control, durability, and rate of penetration, while supporting cost-effective well delivery. This balance between instrumentation and drilling performance is critical to the successful deployment of the in-bit imaging system in operational environments. The new measurement technology was validated through extensive atmospheric testing across varied lithologies and demonstrated robust imaging capability. Field deployment results from various wells are presented. The at-bit images exhibited higher resolution and fidelity, capturing subtle geological features of significance. This paper summarizes the development and validation but focuses on the initial field deployment of this technology, which addresses key limitations of conventional borehole imaging such as sensitivity to mud properties, salinity, and hole size with no additional tools in the BHA while ensuring no additional footprint within the bottom-hole assembly (BHA).