A field-driven, collaborative journey that transformed drilling fluid automation from research concept into a working commercial solution – with real impact for drillers.

Translating research into working technology is a persistent challenge in mineral exploration. What sets Minerals Exploration (MinEx) CRC’s Project 1 – Drilling Optimisation apart is that it has done exactly that – moving from early concept through to active commercial deployment, while remaining grounded in real operational need.

At the centre of this work is Associate Professor Masood Mostofi and a multidisciplinary team based at Curtin University’s Drilling Analytics Research Centre (DARC), working in close partnership with industry. Together, they have redefined how drilling fluid systems can be controlled, automated and embedded into modern drilling operations.

From the outset, the approach was deliberately practical. Rather than developing a solution in isolation, the team worked in live drilling environments, deploying early-stage systems, learning quickly, and refining continuously. Each deployment created an opportunity to test the technology under real conditions – to trial, learn and, where needed, adjust or pivot. This field-based model was critical in moving the technology from concept to something reliable in practice.

A defining aspect of the project – and something Masood is particularly proud of – is its impact on drilling crews. Historically, fluid management has relied heavily on manual handling and operator judgement. The systems developed through MinEx shift that burden, automating monitoring and dosing while improving consistency and reducing exposure to chemicals.

In practice, this has allowed drillers to focus on core drilling activities rather than fluid management. Feedback from the field has pointed to more stable operations, reduced intervention and improved working conditions, outcomes that sit alongside the technical performance gains.

The technology has progressed through a structured but iterative pathway. Early prototyping through iFluid enabled real-world validation across multiple drilling campaigns. This evolved into Hobby, which integrated key functions into a single automated unit, and later into the UN system – a deployment-ready platform now operating across multiple jurisdictions.

Each stage of this progression was tested in active drilling environments, with input from contractors, operators and partners shaping development. This ensured that the technology evolved in line with operational requirements.

Independent field deployments have demonstrated strong performance improvements, including increased metres drilled per shift, reduced water consumption and improved core recovery, without increasing complexity for crews.

Through Frontier Drilling Analytics, the work has transitioned into a structured commercialisation pathway, enabling broader industry adoption. Frontier Drilling Analytics originated from research at Curtin University’s Drilling Analytics Research Centre (DARC) utilising licenced technology from MinEx CRC.

This reflects a core strength of the MinEx CRC model – integrating research, field validation and commercial pathways from the outset.

Andrew Bailey, MinEx CRC Chief Executive Officer, said “Frontier is a strong example of what can be achieved when research, industry and end users work together from the outset. By focusing on real-world deployment and continuous improvement, the team has been able to translate innovation into practical technology that is now making a measurable difference in drilling operations.”

Researchers, engineers, drilling contractors and industry partners have all contributed to developing and refining the system in real conditions. This collaborative, field-driven approach has delivered a complete pathway from concept to commercial reality. Most importantly, it reflects the contribution of Associate Professor Masood Mostofi and the broader team, not only in advancing drilling technology, but in delivering outcomes that make a practical difference for drillers and support safer, more consistent and efficient exploration.

“Technology should make the job easier for the people doing it – that’s where real value is created.”

Key researchers contributing to Project 1 – Drilling Optimisation include:

Associate Professor Masood Mostofi, Dr Thomas Richard, Michael McKenzie, Ryan Forster, Andrew Wurst, Hing Hao Chan, Dr Rui Huang, Associate Professor Dimple Quyn, Rob Brewis, Maryam Abdolahi and Rebecca Fogliani.