Patent Publication Number: US-9896886-B2

Title: Insulation enclosure with compliant independent members

Description:
BACKGROUND 
     The present disclosure relates to oilfield tool manufacturing and, more particularly, to insulation enclosures that help control the thermal profile of drill bits during manufacture. 
     Rotary drill bits are often used to drill oil and gas wells, geothermal wells, and water wells. One type of rotary drill bit is a fixed-cutter drill bit having a bit body comprising matrix and reinforcement materials, i.e., a “matrix drill bit” as referred to herein. Matrix drill bits usually include cutting elements or inserts positioned at selected locations on the exterior of the matrix bit body. Fluid flow passageways are formed within the matrix bit body to allow communication of drilling fluids from associated surface drilling equipment through a drill string or drill pipe attached to the matrix bit body. The drilling fluids lubricate the cutting elements on the matrix drill bit. 
     Matrix drill bits are typically manufactured by placing powder material into a mold and infiltrating the powder material with a binder material, such as a metallic alloy. The various features of the resulting matrix drill bit, such as blades, cutter pockets, and/or fluid-flow passageways, may be provided by shaping the mold cavity and/or by positioning temporary displacement material within interior portions of the mold cavity. A preformed bit blank (or steel shank) may be placed within the mold cavity to provide reinforcement for the matrix bit body and to allow attachment of the resulting matrix drill bit with a drill string. A quantity of matrix reinforcement material (typically in powder form) may then be placed within the mold cavity with a quantity of the binder material. 
     The mold is then placed within a furnace and the temperature of the mold is increased to a desired temperature to allow the binder (e.g., metallic alloy) to liquefy and infiltrate the matrix reinforcement material. The furnace typically maintains this desired temperature to the point that the infiltration process is deemed complete, such as when a specific location in the bit reaches a certain temperature. Once the designated process time or temperature has been reached, the mold containing the infiltrated matrix bit is removed from the furnace. As the mold is removed from the furnace, the mold begins to rapidly lose heat to its surrounding environment via heat transfer, such as radiation and/or convection in all directions, including both radially from a bit axis and axially parallel with the bit axis. Upon cooling, the infiltrated binder (e.g., metallic alloy) solidifies and incorporates the matrix reinforcement material to form a metal-matrix composite bit body and also binds the bit body to the bit blank to form the resulting matrix drill bit. 
     Typically, cooling begins at the periphery of the infiltrated matrix and continues inwardly, with the center of the bit body cooling at the slowest rate. Thus, even after the surfaces of the infiltrated matrix of the bit body have cooled, a pool of molten material may remain in the center of the bit body. As the molten material cools, there is a tendency for shrinkage that could result in voids forming within the bit body unless molten material is able to continuously backfill such voids. In some cases, for instance, one or more intermediate regions within the bit body may solidify prior to adjacent regions and thereby stop the flow of molten material to locations where shrinkage porosity is developing. In other cases, shrinkage porosity may result in poor metallurgical bonding at the interface between the bit blank and the molten materials, which can result in the formation of cracks within the bit body that can be difficult or impossible to inspect. When such bonding defects are present and/or detected, the drill bit is often scrapped during or following manufacturing or the lifespan of the drill bit may be dramatically reduced. If these defects are not detected and the drill bit is used in a job at a well site, the bit can fail and/or cause damage to the well including loss of rig time. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following figures are included to illustrate certain aspects of the present disclosure and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, without departing from the scope of this disclosure. 
         FIG. 1  illustrates an exemplary fixed-cutter drill bit that may be fabricated in accordance with the principles of the present disclosure. 
         FIGS. 2A-2C  illustrate progressive schematic diagrams of an exemplary method of fabricating a drill bit, in accordance with the principles of the present disclosure. 
         FIG. 3  illustrates a cross-sectional side view of an exemplary insulation enclosure, according to one or more embodiments. 
         FIGS. 4A-4C  illustrate cross-sectional side views of various embodiments of another exemplary insulation enclosure, according to one or more embodiments. 
         FIGS. 5A-5E  illustrate various cross-sectional top views of exemplary insulation enclosures, according to one or more embodiments. 
         FIGS. 6A-6C  illustrate cross-sectional top views of another exemplary insulation enclosure, according to one or more embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure relates to oilfield tool manufacturing and, more particularly, to insulation enclosures that help control the thermal profile of drill bits during manufacture. 
     Disclosed are embodiments of insulation enclosures configured to help control the thermal profile of a matrix drill bit mold, and thereby aid in directional solidification of molten contents within the mold. The insulation enclosure may include an internal shell that provides multiple independently moveable members (e.g., walls) configured to engage the outer surfaces of the mold. In at least some embodiment, the independently moveable walls may allow a given insulation enclosure (i.e., “hot hat”) to be compatible with a range of mold dimensions (e.g., diameter and height), rather than a specific mold diameter. Independently moveable walls may also ensure that the insulation enclosure does not tip over the mold while being lowered, and help ensure the mold is centered within the insulation enclosure. The independently moveable members may also ensure intimate contact with or close, controlled positioning next to the mold during the cooling process. Biasing members coupled to the independently moveable members may also be strategically positioned to control or affect the range of movement of the independently moveable members. For example, compliant devices may be coupled to the independently moveable members such that the independently moveable members have a greater range of movement toward the bottom of the insulation enclosure, with less or no range of movement near the top, to provide sufficient clearance in the can to accommodate a mold without excessive “play” in the independently moveable members. 
     Because the independently movable members are able to physically engage the outer surfaces of the mold, the mold may be predominantly cooled via conduction alternatively or in addition to radiation or convection. As will be appreciated, radiative heat flux is strongly dependent on temperature and significant as compared to conductive heat flux at high temperatures. As a result, the embodiments disclosed herein may facilitate a more controlled cooling process that helps optimize the directional solidification of the molten contents within the mold, thus preventing shrinkage porosity. Through directional solidification, any potential defects may be pushed or urged toward the top regions of the mold where they can subsequently be machined off during finishing operations. Moreover, since the independent members may be radially movable and otherwise compliant, the insulation enclosure may be able to accommodate a wider range of mold sizes than what is currently possible with existing insulation enclosure designs. 
       FIG. 1  illustrates a perspective view of an example of a fixed-cutter drill bit  100  that may be fabricated in accordance with the principles of the present disclosure. As illustrated, the fixed-cutter drill bit  100  (hereafter “the drill bit  100 ”) may include or otherwise define a plurality of cutter blades  102  arranged along the circumference of a bit head  104 . The bit head  104  is connected to a shank  106  to form a bit body  108 . The shank  106  may be connected to the bit head  104  by welding, such as using laser arc welding that results in the formation of a weld  110  around a weld groove  112 . The shank  106  may further include or otherwise be connected to a threaded pin  114 , such as an American Petroleum Institute (API) drill pipe thread. 
     In the depicted example, the drill bit  100  includes five cutter blades  102 , in which multiple pockets or recesses  116  (also referred to as “sockets” and/or “receptacles”) are formed. Cutting elements  118 , otherwise known as inserts, may be fixedly installed within each recess  116 . This can be done, for example, by brazing each cutting element  118  into a corresponding recess  116 . As the drill bit  100  is rotated in use, the cutting elements  118  engage the rock and underlying earthen materials, to dig, scrape or grind away the material of the formation being penetrated. 
     During drilling operations, drilling fluid (commonly referred to as “mud”) can be pumped downhole through a drill string (not shown) coupled to the drill bit  100  at the threaded pin  114 . The drilling fluid circulates through and out of the drill bit  100  at one or more nozzles  120  positioned in nozzle openings  122  defined in the bit head  104 . Formed between each adjacent pair of cutter blades  102  are junk slots  124 , along which cuttings, downhole debris, formation fluids, drilling fluid, etc., may pass and circulate back to the well surface within an annulus formed between exterior portions of the drill string and the interior of the wellbore being drilled (not expressly shown). 
       FIGS. 2A-2C  are schematic diagrams that sequentially illustrate an example method of fabricating a drill bit, such as the drill bit  100  of  FIG. 1 , in accordance with the principles of the present disclosure. In  FIG. 2A , a mold  200  is placed within a furnace  202 . While not specifically depicted in  FIGS. 2A-2C , the mold  200  may include and otherwise contain all the necessary materials and component parts required to produce a drill bit including, but not limited to, reinforcement materials, a binder material, displacement materials, a bit blank, etc. 
     For some applications, two or more different types of matrix reinforcement materials or powders may be positioned in the mold  200 . Examples of such matrix reinforcement materials may include, but are not limited to, tungsten carbide, monotungsten carbide (WC), ditungsten carbide (W 2 C), macrocrystalline tungsten carbide, other metal carbides, metal borides, metal oxides, metal nitrides, natural and synthetic diamond, and polycrystalline diamond (PCD). Examples of other metal carbides may include, but are not limited to, titanium carbide and tantalum carbide, and various mixtures of such materials may also be used. Various binder (infiltration) materials that may be used include, but are not limited to, metallic alloys of copper (Cu), nickel (Ni), manganese (Mn), lead (Pb), tin (Sn), cobalt (Co) and silver (Ag). Phosphorous (P) may sometimes also be added in small quantities to reduce the melting temperature range of infiltration materials positioned in the mold  200 . Various mixtures of such metallic alloys may also be used as the binder material. 
     The temperature of the mold  200  and its contents are elevated within the furnace  202  until the binder liquefies and is able to infiltrate the matrix material. Once a specified location in the mold  200  reaches a certain temperature in the furnace  202 , or the mold  200  is otherwise maintained at a particular temperature within the furnace  202  for a predetermined amount of time, the mold  200  is then removed from the furnace  202 . Upon being removed from the furnace  202 , the mold  200  immediately begins to lose heat by radiating thermal energy to its surroundings while heat is also convected away by cold air from outside the furnace  202 . In some cases, as depicted in  FIG. 2B , the mold  200  may be transported to and set down upon a thermal heat sink  206 . The radiative and convective heat losses from the mold  200  to the environment continue until an insulation enclosure  208  is lowered around the mold  200 . 
     The insulation enclosure  208  may be a rigid shell or structure used to insulate the mold  200  and thereby slow the cooling process. In some cases, the insulation enclosure  208  may include a hook  210  attached to a top surface thereof. The hook  210  may provide an attachment location, such as for a lifting member, whereby the insulation enclosure  208  may be grasped and/or otherwise attached to for transport. For instance, a chain or wire  212  may be coupled to the hook  210  to lift and move the insulation enclosure  208 , as illustrated. In other cases, a mandrel or other type of manipulator (not shown) may grasp onto the hook  210  to move the insulation enclosure  208  to a desired location. 
     In some embodiments, the insulation enclosure  208  may include an outer frame  214 , an inner frame  216 , and insulation material  218  positioned between the outer and inner frames  214 ,  216 . In some embodiments, both the outer frame  214  and the inner frame  216  may be made of rolled steel and shaped (i.e., bent, welded, etc.) into the general shape, design, and/or configuration of the insulation enclosure  208 . In other embodiments, the inner frame  216  may be a metal wire mesh that holds the insulation material  218  between the outer frame  214  and the inner frame  216 . The insulation material  218  may be selected from a variety of insulative materials, such as those discussed below. In at least one embodiment, the insulation material  218  may be a ceramic fiber blanket, such as INSWOOL® or the like. 
     As depicted in  FIG. 2C , the insulation enclosure  208  may enclose the mold  200  such that thermal energy radiating from the mold  200  is dramatically reduced from the top and sides of the mold  200  and is instead directed substantially downward and otherwise toward/into the thermal heat sink  206  or back towards the mold  200 . In the illustrated embodiment, the thermal heat sink  206  is a cooling plate designed to circulate a fluid (e.g., water) at a reduced temperature relative to the mold  200  (i.e., at or near ambient) to draw thermal energy from the mold  200  and into the circulating fluid, and thereby reduce the temperature of the mold  200 . In other embodiments, however, the thermal heat sink  206  may be any type of cooling device or heat exchanger configured to encourage heat transfer from the bottom  220  of the mold  200  to the thermal heat sink  206 . In yet other embodiments, the thermal heat sink  206  may be any stable or rigid surface that may support the mold  200 , and preferably having a high thermal capacity, such as a concrete slab or flooring. 
     Accordingly, once the insulation enclosure  208  is arranged about the mold  200  and the thermal heat sink  206  is operational, the majority of the thermal energy is transferred away from the mold  200  through the bottom  220  of the mold  200  and into the thermal heat sink  206 . This controlled cooling of the mold  200  and its contents (i.e., the matrix drill bit) allows a user to regulate or control the thermal profile of the mold  200  to a certain extent and may result in directional solidification of the molten contents of the drill bit positioned within the mold  200 , where axial solidification of the drill bit dominates its radial solidification. Within the mold  200 , the face of the drill bit (i.e., the end of the drill bit that includes the cutters) may be positioned at the bottom  220  of the mold  200  and otherwise adjacent the thermal heat sink  206  while the shank  106  ( FIG. 1 ) may be positioned adjacent the top of the mold  200 . As a result, the drill bit may be cooled axially upward, from the cutters  118  ( FIG. 1 ) toward the shank  106  ( FIG. 1 ). Such directional solidification (from the bottom up) may prove advantageous in reducing the occurrence of voids due to shrinkage porosity, cracks at the interface between the bit blank and the molten materials, and nozzle cracks. 
     While  FIG. 1  depicts a fixed-cutter drill bit  100  and  FIGS. 2A-2C  discuss the production of a generalized drill bit within the mold  200 , the principles of the present disclosure are equally applicable to any type of oilfield drill bit or cutting tool including, but not limited to, fixed-angle drill bits, roller-cone drill bits, coring drill bits, bi-center drill bits, impregnated drill bits, reamers, stabilizers, hole openers, cutters, cutting elements, and the like. Moreover, it will be appreciated that the principles of the present disclosure may further apply to fabricating other types of tools and/or components formed, at least in part, through the use of molds. For example, the teachings of the present disclosure may also be applicable, but not limited to, non-retrievable drilling components, aluminum drill bit bodies associated with casing drilling of wellbores, drill-string stabilizers, cones for roller-cone drill bits, models for forging dies used to fabricate support arms for roller-cone drill bits, arms for fixed reamers, arms for expandable reamers, internal components associated with expandable reamers, sleeves attached to an uphole end of a rotary drill bit, rotary steering tools, logging-while-drilling tools, measurement-while-drilling tools, side-wall coring tools, fishing spears, washover tools, rotors, stators and/or housings for downhole drilling motors, blades and housings for downhole turbines, and other downhole tools having complex configurations and/or asymmetric geometries associated with forming a wellbore. 
     According to the present disclosure, controlling the thermal profile of the mold  200  may be enhanced by altering the configuration and/or design of the insulation enclosure  208 . More specifically, the embodiments described herein provide an insulation enclosure that includes an internal shell having multiple independently movable members configured to engage the outer surface of the mold  200 . The independent members may be radially movable and otherwise compliant and, therefore, able to accommodate a wider range of mold  200  sizes than what is currently possible with existing insulation enclosure designs. The independent members are able to accommodate and physically engage the outer surface of the mold  200 , to eliminate or at least reduce or minimize any gap and any corresponding air cavity between the mold  200  and the insulative features of the insulation enclosure. This reliable engagement between the insulating features and the mold  200  helps increase or maximize conductive heat transfer, while reducing or minimizing cooling by radiation and/or convection. Since radiative heat flux is strongly dependent on temperature and is significant compared to conductive heat flux at high temperatures, the embodiments disclosed herein may facilitate a more controlled cooling process for the mold  200  and optimize the directional solidification of the molten contents within the mold  200  (e.g., a drill bit). Through directional solidification, any potential defects (e.g., voids) may be pushed or otherwise urged toward the top regions of the mold where they can be machined off later during finishing operations. 
       FIG. 3  is a cross-sectional side view of an exemplary insulation enclosure  300 , according to one or more embodiments. The insulation enclosure  300  may be similar in some respects to the insulation enclosure  208  of  FIGS. 2B and 2C , and therefore may be further understood with reference to those figures as well, where like numerals indicate like elements or components not described again. As illustrated, the insulation enclosure  300  may include an outer shell  302  and an inner shell  304  positioned within the outer shell  302 . 
     In some embodiments, the outer shell  302  may be a rigid structure configured to provide structural support for the inner shell  304 . For instance, the outer shell  302  may be made of a rigid material, such as rolled steel, and fabricated (e.g., bent, welded, etc.) into the general shape, design, and configuration capable of accommodating the inner shell  304  therein. In some embodiments, the outer shell  302  may be substantially similar to the insulation enclosure  208  of  FIGS. 2B and 2C . For instance, the outer shell  302  may include the outer frame  214 , the inner frame  216 , and insulation material  218  positioned therebetween. 
     The outer shell  302  may be configured and otherwise sized to receive the inner shell  304  and the mold  200  therein. To accomplish this, the outer shell  302  may be generally cylindrical and have an open end  305   a  and a top end  305   b . The open end  305   a  may be shaped so as to be able to receive the inner shell  304  and the mold  200 , and the top end  305   b  may provide the hook  210  described above. The outer shell  302  may exhibit any suitable horizontal cross-sectional shape that will accommodate the shape of the inner shell  304  including, but not limited to, circular, ovular, polygonal, polygonal with rounded corners, or any hybrid thereof. In some embodiments, the outer shell  302  may exhibit different horizontal cross-sectional shapes and/or sizes at different vertical locations. 
     The inner shell  304  may include or otherwise provide a plurality of independent members  306  (shown as members  306   a ,  306   b , and  306   c ) that allow the internal shell  304  to move independent of and with respect to the outer shell  302 . In the illustrated embodiment, the first and second members  306   a,b  may be characterized and otherwise referred to as sidewall members of the inner shell  304 , and the third member  306   c  may be characterized and otherwise referred to as a top member of the inner shell  304 . While only two sidewall members  306   a,b  are depicted in  FIG. 3 , more than two sidewall members  306   a,b  may be employed, as discussed below. 
     Each sidewall and top member  306   a - c  may be movably coupled to the inner surface (e.g., the inner frame  216 ) of the outer shell  302 . For instance, in some embodiments, the sidewall and top members  306   a - c  may be coupled to the inner frame  216  with a coupling member such as, for example, a hinge, track, or support member. Alternatively, or in addition thereto, the sidewall and top members  306   a - c  may be movably coupled to the inner frame  216  with one or more compliant devices  308 , which may bias movement of sidewall and top members  306   a - c . In yet other embodiments, as will be assumed in the present discussion, the compliant devices  308  may each be independent biasing members that couple the sidewall and top members  306   a - c  to the inner frame  216 . The compliant devices  308  in this embodiment may be configured to bias and otherwise urge each corresponding sidewall and top member  306   a - c  against an adjacent outer surface of the mold  200 . The sidewall and top members  306   a - c  may be physically and structurally independent from each other so that each can conform to varying adjacent outer surfaces of the mold  200 . 
     It should be noted that while two compliant devices  308  are depicted in  FIG. 3  as being attached to each sidewall and top member  306   a - c , it will be appreciated that more or less than two compliant devices  308  may be employed, without departing from the scope of the disclosure. In some embodiments, for instance, the compliant devices  308  may be strategically positioned to control or affect the range of movement of the sidewall and top members  306   a - c . In at least one embodiment, the compliant devices  308  may be arranged such that the sidewall members  306   a,b  members have a greater range of movement toward the open end  305   a.    
     In the illustrated embodiment, the compliant devices  308  are springs, such as coil springs, leaf springs, or the like. In other embodiments, however, the compliant devices  308  may be any type of compliant member, device, or mechanism capable of biasing the sidewall and top members  306   a - c  against the adjacent outer surfaces of the mold  200 . In at least one embodiment, for example, one or more of the compliant devices  308  may be an actuation device, such as an air cylinder configured to be pressurized and otherwise actuated to force the sidewall and top members  306   a - c  against the outer surface of the mold  200 . In other embodiments, one or more of the compliant devices  308  may be a piston solenoid assembly configured to be actuated such that a piston extends radially to force the sidewall and top members  306   a - c  against the outer surface of the mold  200 . Those skilled in the art will readily appreciate the several different variations and/or types of actuation devices (i.e., mechanical, electromechanical, electrical, hydraulic, pneumatic, etc.) that may be used as compliant devices  308  to achieve the ends of the present disclosure. 
     In yet other embodiments, two or more compliant devices  308  may be used to connect a given sidewall or top member  306   a - c  and may be differing types of compliant devices  308 . For example, one compliant device  308  may be an actuated piston and a second compliant device may be a spring. In such an embodiment, the two compliant devices  308  may prove advantageous in slanting a sidewall member  306   a,b  so that the opening between sidewall members near the base is sufficient to accept the mold  200  while the opening between sidewall members at the top of the mold  200  does not change size. Such hybrid compliant/actuation designs could produce certain advantages, such as lower-cost designs, reduced controlling requirements, and assistance in ensuring proper alignment of the insulation enclosure  300  as it lowers. Additional description of the compliant members is given below. 
     Each sidewall and top member  306   a - c  may be a composite structure made of a support member  310  and insulation material  312  positioned on the support member  310 . Having the insulation material  312  positioned on the support member  310  may include the insulation material  312  being coupled to, supported by, and/or in contact with the support member  310  via various configurations. The support member  310  may be made of any rigid material including, but not limited to, metals, ceramics (e.g., a molded ceramic substrate), composite materials, combinations thereof, and the like. In at least one embodiment, the support member  310  may be a metal mesh. In the illustrated embodiment, the insulation material  312  may be attached to the support member  310  using, for example, one or more mechanical fasteners  314  (e.g., screws, bolts, pins, etc.). In other embodiments, however, the insulation material  312  may be attached to the support member  310  using welding or brazing techniques, or combination of welding, brazing and/or mechanical fasteners  314 . In other embodiments, as discussed below, the support member  310  may be configured to support the insulation material  312  with a footing  420  ( FIG. 4A ) and thereby maintain the insulation material  312  in place, perhaps without the use of a fastening or joining method. 
     The insulation material  312  may include, but is not limited to, ceramics (e.g., oxides, carbides, borides, nitrides, and silicides that may be crystalline, non-crystalline, or semi-crystalline), polymers, insulating metal composites, carbons, nanocomposites, foams, fluids (e.g., air), any composite thereof, or any combination thereof. The insulation material  312  may further include, but is not limited to, materials in the form of beads, particulates, flakes, fibers, wools, woven fabrics, bulked fabrics, sheets, bricks, stones, blocks, cast shapes, molded shapes, foams, sprayed insulation, and the like, any hybrid thereof, or any combination thereof. Accordingly, examples of suitable materials that may be used as the insulation material  312  may include, but are not limited to, ceramics, ceramic fibers, ceramic fabrics, ceramic wools, ceramic beads, ceramic blocks, moldable ceramics, woven ceramics, cast ceramics, fire bricks, carbon fibers, graphite blocks, shaped graphite blocks, polymer beads, polymer fibers, polymer fabrics, nanocomposites, fluids in a jacket, metal fabrics, metal foams, metal wools, metal castings, and the like, any composite thereof, or any combination thereof. 
     Suitable materials that may be used as the insulation material  312  may be capable of maintaining the mold  200  at temperatures ranging from a lower limit of about −200° C. (−325° F.), −100° C. (−150° F.), 0° C. (32° F.), 150° C. (300° F.), 175° C. (350° F.), 260° C. (500° F.), 400° C. (750° F.), 480° C. (900° F.), or 535° C. (1000° F.) to an upper limit of about 870° C. (1600° F.), 815° C. (1500° F.), 705° C. (1300° F.), 535° C. (1000° F.), 260° C. (500° F.), 0° C. (32° F.), or −100° C. (−150° F.), wherein the temperature may range from any lower limit to any upper limit and encompass any subset therebetween. Moreover, suitable materials that may be used as the insulation material  312  may be able to withstand temperatures ranging from a lower limit of about −200° C. (−325° F.), −100° C. (−150° F.), 0° C. (32° F.), 150° C. (300° F.), 260° C. (500° F.), 400° C. (750° F.), or 535° C. (1000° F.) to an upper limit of about 870° C. (1600° F.), 815° C. (1500° F.), 705° C. (1300° F.), 535° C. (1000° F.), 0° C. (32° F.), or −100° C. (−150° F.), wherein the temperature may range from any lower limit to any upper limit and encompass any subset therebetween. Those skilled in the art will readily appreciate that the insulation material  312  may be appropriately chosen for the particular application and temperature to be maintained within the insulation enclosure  300 . Moreover, the examples of the insulation material  312  may equally apply to the insulation material  218  (if used) of the outer shell  302 . 
     In some embodiments, in addition to the materials mentioned above or independent thereof, a reflective coating or material may be positioned on the inner surfaces of one or more of the sidewall and top members  306   a - c  or the outer shell  302 . More particularly, the reflective coating or material may be adhered to and/or sprayed onto the inner surface of one or more of the support members  310  or the outer shell  302  to reflect an amount of thermal energy being emitted either from the mold  200  back toward the mold  200  or from the insulation material  312  back toward the insulation material  312 . Furthermore, an insulative coating, such as a thermal barrier coating, may be applied to the inner and/or outer surfaces of the support members  310 , insulation material  312 , or outer shell  302 . Such an insulative coating could provide a thermal barrier between adjacent materials, such as the mold  200  and the support members  310 , or the support members  310  and the insulation material  312 , or could otherwise provide resistance to radiation heat transfer between the insulation material  312  and the outer shell  302  or the compliant devices  308 . In other embodiments, or in addition thereto, the inner surface of one or more of the support members  310  may be polished so as to increase its emissivity. 
     Exemplary operation of the insulation enclosure  300  is now provided. As described above, the mold  200  may be removed from the furnace  202  ( FIG. 2A ) and placed on a thermal heat sink  206  ( FIGS. 2B and 2C ) to initiate directional cooling and solidification of the molten contents within the mold  200 . The insulation enclosure  300  may then be lowered around the mold  200  using, for example, the hook  210  and the wire  212  or any other type of device that may be able to grasp onto the hook  210  or any portion of the insulation enclosure  300 . 
     As the insulation enclosure  300  is lowered over the mold  200 , the internal shell  304  may allow for movement with respect to the outer shell  302  to provide sufficient clearance around the mold  200 . More particularly, the sidewall and top members  306   a - c  may be able to move as biased and optionally coupled to the compliant devices  308 , so the insulation enclosure  300  may accommodate the particular size and shape of the mold  200 . Once fully lowered over the mold  200 , the sidewall and top members  306   a - c  may physically contact adjacent outer surfaces of the mold  200  and urged by the compliant devices  308  to maintain such physical contact. In embodiments where one or more of the compliant devices  308  is an actuation device, the compliant devices  308  may be physically retracted while the insulation enclosure  300  is lowered over the mold  200  so as to accommodate the size and shape of the mold  200 . Once the insulation enclosure  300  is fully lowered around the mold  200 , the compliant devices  308  may be actuated to maintain the sidewall and top members  306   a - c  in physical contact with adjacent outer surfaces of the mold  200 . 
     Having the sidewall and top members  306   a - c  movably and/or compliantly engaged to the outer shell  302  may help prevent the mold  200  from being tipped over or damaged as the insulation enclosure  300  is lowered around the mold  200 . Moreover, since the sidewall and top members  306   a - c  are movable, the insulation enclosure  300  may be able to accommodate a wider range of mold  200  sizes, which equates to the ability to manufacture a wider size range of drill bits, tools, or other components by employing the principles of the present disclosure. 
     With the sidewall and top members  306   a - c  in physical contact with the mold  200 , the thermal energy transferred from the mold  200  via radiation and/or convection may be minimized or completely reduced such that the thermal energy of the mold  200  is significantly transferred via conduction from the top and sides of the mold  200  through conduction in the mold  200  (and potentially the inner shell  304 ) substantially downward and otherwise toward/into the thermal heat sink  206  via the bottom  220  of the mold  200 . As a result, the thermal profile of the mold  200  (and its molten contents) may be controlled such that directional solidification of the molten contents within the mold  200  is substantially achieved in the axial direction (e.g., toward the bottom  220  of the mold  200 ) rather than the radial direction (through the sides of the mold  200 ). Accordingly, cooling of the mold  200  may be generally facilitated axially upward, from the bottom  220  of the mold  200  toward the top member  306   c  of the inner shell  304 . 
     In the illustrated embodiment, the support members  310  are depicted as being positioned on the interior of the inner shell  304  and otherwise in direct contact with adjacent outer portions of the mold  200 , and the insulation material  312  is depicted as being positioned on the exterior of the inner shell  304 . In such embodiments, the compliant devices  308  may be attached to the inner surface of the outer shell  302  at one end and attached at the other end to either the insulation material  312  or extend through the insulation material  312  to be coupled to the corresponding support member  310 . 
       FIGS. 4A-4C  are cross-sectional side views of various embodiments or configurations of an insulation enclosure  400 . The insulation enclosure  400  may be substantially similar to the insulation enclosure  300  of  FIG. 3  and therefore may be best understood with reference also to  FIG. 3 , where like numerals represent like elements or components not described again in detail. Similar to the insulation enclosure  300  of  FIG. 3 , the insulation enclosure  400  of  FIGS. 4A-4C  may include the outer shell  302  and the inner shell  304 , where the inner shell  304  includes the plurality of sidewall and top members  306   a - c  that allow the internal shell  304  to move independent of and with respect to the outer shell  302 . Moreover, each sidewall and top member  306   a - c  may be movably or compliantly coupled to the inner surface of the outer shell  302  using one or more compliant devices  308 . 
     Unlike the insulation enclosure  300  of  FIG. 3 , however, the sidewall and top members  306   a - c  in the insulation enclosure  400  of  FIGS. 4A-4C  may exhibit different designs or configurations. More particularly, and with reference to  FIG. 4A , the support members  310  of each sidewall and top member  306   a - c  may be positioned on the exterior of the inner shell  304  while the insulation material  312  is urged into direct contact with adjacent outer portions of the mold  200  with the compliant devices  308 . In such embodiments, the compliant devices  308  may be attached to the inner surface of the outer shell  302  at one end and directly attached at the other end to the corresponding support member  310 . 
     Moreover, in at least one embodiment, the support members  310  of the sidewall members  306   a,b  may include a footing  402  that extends substantially horizontal. The footing  402  may serve as a support for the insulation material  312  and may prove especially useful when the insulation material  312  includes stackable and/or individual component materials such as ceramic blocks or rings, moldable ceramics, cast ceramics, fire bricks, graphite blocks or rings, shaped graphite blocks, metal castings, and any combination thereof. As will be appreciated, the footings  402  may equally be applied to the insulation enclosure  300  of  FIG. 3 , without departing from the scope of the disclosure. 
     With reference to  FIG. 4B , the support members  310  of the sidewall members  306   a,b  may be positioned on both the interior and exterior of the inner shell  304 , and thereby defining a cavity configured to receive the insulation material  312  therein. More particularly, the support members  310  of the sidewall members  306   a,b  may each include an inner support member  404   a  and an outer support member  404   b  radially offset from the inner support member  404   a  so as to accommodate the insulation material  312  therebetween. One or both of the sidewall members  306   a,b  may further include the footing  402  positioned at the bottom thereof and configured to support insulation material  312  that may be stackable and/or consist of individual component materials. The footing  402  may extend horizontally from either the inner or outer support members  404   a,b  or otherwise extend therebetween. 
     With continued reference to  FIG. 4B , in at least one embodiment, a thermal element  406  may be in thermal communication with the top member  306   c . The thermal element  406  may be any device or mechanism configured to impart thermal energy to the mold  200  and, more particularly, through the top of the mold  200 . For example, the thermal element  406  may be, but is not limited to, a heating element, a heat exchanger, a radiant heater, an electric heater, an infrared heater, an induction heater, a heating band, heated coils, heated fluids (flowing or static), an exothermic chemical reaction, or any combination thereof. Suitable configurations for a heating element may include, but not be limited to, coils, plates, strips, finned strips, and the like, or any combination thereof. 
     The thermal element  406  may be in thermal communication with the top member  306   c  via a variety of configurations. In the illustrated embodiment, for instance, the thermal element  406  is depicted as being embedded within the insulation material  312  of the top member  306   c . In other embodiments, however, the thermal element  406  may interpose the insulation material  312  and the corresponding support member  310 , interpose the top member  306   c  and the top of the mold  200 , or interpose the top member  306   c  and the inner surface of the top of the outer shell  302 , without departing from the scope of the disclosure. The thermal element  406  may be useful in helping facilitate the directional solidification of the molten contents of the mold  200  as it provides thermal energy to the top of the mold  200 , while the thermal heat sink  206  draws thermal energy out the bottom  220  of the mold  200 . 
     In some embodiments, one or more additional thermal elements (not shown) may also be placed in relation to the sidewall members  306   a,b  to facilitate directional cooling of the mold  200 . For example, such thermal elements could be placed along the top third of the outer side surface of the mold  200  and could act in conjunction with or independent of the thermal element  406  that may be placed in relation to the top member  306   c.    
     With reference to  FIG. 4C , the sidewalls or sidewall members  306   a,b  of the inner shell  304  may be divided and otherwise include multiple sidewall segments  408  (shown as sidewall segments  408   a ,  408   b ,  408   c ,  408   d ,  408   e , and  408   f ) stacked atop each other. As illustrated, the sidewall segments  408   a - f  are depicted as being stacked vertically and otherwise in direct contact with vertically adjacent sidewall segments  408   a - f . Each sidewall segment  408   a - f  may be movably or compliantly coupled to the inner surface of the outer shell  302  using one or more compliant devices  308 . As a result, each sidewall segment  408   a - f  may be independent of any adjacent sidewall segment  408   a - f  and otherwise separately engageable on the adjacent outer surfaces of the mold  200  as the insulation enclosure  400  is dropped over the mold  200 . 
     Each sidewall segment  408   a - f  may include a support member  310  and insulation material  312  in accordance with any of the embodiments described herein. For instance, while the sidewall segments  408   a - f  depict the support member  310  as being positioned on the interior of the inner shell  304  with the insulation material  312  on the exterior of the inner shell  304 , embodiments are contemplated herein where the support member  310  is positioned on the exterior of the inner shell  304  with the insulation material  312  on the interior thereof and adjacent the mold  200 . In yet other embodiments, one or more of the sidewall segments  408   a - f  may be similar to the sidewall members  306   a,b  depicted in  FIG. 4B , and include inner and outer support members  404   a,b  ( FIG. 4B ) with the insulation material  312  being positioned therebetween, without departing from the scope of the disclosure. 
     The size and/or thickness of the sidewall segments  408   a - f  may vary, depending on the application to advantageously alter the thermal resistance of each sidewall segment  408   a - f , and thereby help control the thermal profile of the molten contents within the mold  200 . In at least one embodiment, for instance, the thickness of the insulation material  312  corresponding to the lower sidewall segments  408   c  and  408   f  at or near the bottom  220  may be less than the thickness of the insulation material  312  corresponding to the upper sidewall segments  408   a  and  408   d  at or near the top of the mold  200 . As a result, the thermal resistance of the lower sidewall segments  408   c  and  408   f  may be less than the thermal resistance of the upper sidewall segments  408   a  and  408   d.    
     Alternatively, the thermal resistance of the sidewall segments  408   a - f  may be regulated or otherwise altered by using different types of insulation material  312 . For example, the insulation material  312  corresponding to the lower sidewall segments  408   c  and  408   f  may exhibit a first thermal resistance and the insulation material  312  corresponding to the upper sidewall segments  408   a  and  408   d  may exhibit a second thermal resistance, where the first thermal resistance is less than the second thermal resistance. 
     As will be appreciated, any of the above-described embodiments and/or features depicted in  FIGS. 3 and 4A-4C  may be interchangeable and/or duplicated, without departing from the scope of the disclosure. Moreover, exemplary operation of the insulation enclosure  400  depicted in  FIGS. 4A-4C  may be substantially similar to the operation of the insulation enclosure  300  of  FIG. 3 , and therefore will not be described again. 
       FIGS. 5A-5E  are various cross-sectional top views of exemplary insulation enclosures, according to one or more embodiments. Each insulation enclosure depicted in  FIGS. 5A-5E  may be similar to (or the same as) one or both of the insulation enclosures  300  and  400  described above with reference to  FIGS. 3 and 4A-4C . Accordingly, the insulation enclosures of  FIGS. 5A-5E  may be further understood with reference to the insulation enclosures  300 ,  400  of those other figures, where like numerals will indicate like elements or components that will not be described again in detail. In the embodiments of  FIGS. 5A-5E , the mold  200  is depicted as exhibiting a substantially circular cross-section. Those skilled in the art will readily appreciate, however, that the mold  200  may alternatively exhibit other cross-sectional shapes including, but not limited to, ovular, polygonal, polygonal with rounded corners, or any hybrid thereof. 
     In  FIG. 5A , an exemplary insulation enclosure  500  is depicted as having a substantially square horizontal cross-sectional shape. More particularly, the outer shell  302  may be square and the inner shell  304  may also be square in shape and include four sidewall members  502  (shown as sidewall members  502   a ,  502   b ,  502   c , and  502   d ). While not specifically labeled, similar to the sidewall members  306   a,b  of  FIGS. 3 and 4A-4C , each sidewall member  502   a - d  may be a composite structure made of a support member  310  ( FIGS. 3 and 4A-4C ) and insulation material  312  ( FIGS. 3 and 4A-4C ). 
     The sidewall members  502   a - d  may each be movably and/or compliantly coupled to corresponding inner surfaces of the outer shell  302  using one or more compliant devices  308 . As a result, movement of each sidewall member  502   a - d  may be independent of movement of any adjacent sidewall member  502   a - d  and otherwise separately engageable on the outer surface of the mold  200  as the insulation enclosure  500  is dropped over the mold  200 . 
     The inner shell  304  may further include a top member  504  (shown in dashed and phantom lines). In some embodiments, the top member  504  may also exhibit a generally square shape, as depicted. In such embodiments, the sidewall members  502   a - d  and the top member  504  may cooperatively define a box-like structure. In other embodiments, however, the top member  504  may exhibit other shapes including, but not limited to, circular, ovular, or any other polygonal shape sufficient to substantially cover the top of the sidewall member  502   a - d.    
     While not specifically labeled, similar to the top member  306   c  of  FIGS. 3 and 4A-4C , the top member  504  may be a composite structure made of a support member  310  ( FIGS. 3 and 4A-4C ) and insulation material  312  ( FIGS. 3 and 4A-4C ). Moreover, similar to the top member  306   c  of  FIGS. 3 and 4A-4C , the top member  504  may be movably or compliantly coupled to a top inner surface of the outer shell  302  with one or more compliant devices  308  (not shown for the top member  504 ). 
     In  FIG. 5B , another exemplary insulation enclosure  510  is depicted as exhibiting a substantially octagonal horizontal cross-sectional shape. More particularly, the outer shell  302  may be octagonal and the inner shell  304  may also be octagonal in shape by including eight sidewall members  506  (shown as sidewall members  506   a ,  506   b ,  506   c ,  506   d ,  506   e ,  506   f ,  506   g , and  506   h ). While not specifically labeled, each sidewall member  506   a - h  may be a composite structure made of a support member  310  ( FIGS. 3 and 4A-4C ) and insulation material  312  ( FIGS. 3 and 4A-4C ). 
     The sidewall members  506   a - h  may each be movably or compliantly coupled to corresponding inner surfaces of the outer shell  302  using one or more compliant devices  308 . As a result, each sidewall member  506   a - h  may be independent of any adjacent sidewall member  506   a - h  and otherwise separately engageable on adjacent outer surfaces of the mold  200  as the insulation enclosure  510  is dropped over the mold  200 . In some applications, the octagonal shape of the insulation enclosure  510  may allow more contact with the mold  200  than with the square shape of the insulation enclosure  500 . As a result, the insulation enclosure  510  may be able to more efficiently or effectively regulate the thermal profile of the mold  200  by increasing or maximizing heat transfer via conduction rather than via radiation. 
     The inner shell  304  may further include a top member  508  (shown in dashed and phantom lines). In some embodiments, the top member  508  may also exhibit a generally octagonal shape, but may equally be circular, ovular, or any other polygonal shape, without departing from the scope of the disclosure. The top member  508  may be movably or compliantly coupled to a top inner surface of the outer shell  302  with one or more compliant devices  308  (not shown for the top member  508 ). Moreover, while not specifically labeled, the top member  508  may be a composite structure made of a support member  310  ( FIGS. 3 and 4A-4C ) and insulation material  312  ( FIGS. 3 and 4A-4C ). 
     In  FIG. 5C , another exemplary insulation enclosure  520  is provided and exhibits a substantially circular horizontal cross-sectional shape. More particularly, the outer shell  302  may be circular and the inner shell  304  may also be circular in shape and include two arcuate sidewall members  512  (shown as sidewall members  512   a  and  512   b ). As used herein, the term “arcuate” refers to an arc-like structure or segment. While not specifically labeled, each arcuate sidewall member  512   a,b  may be a composite structure made of a support member  310  ( FIGS. 3 and 4A-4C ) and insulation material  312  ( FIGS. 3 and 4A-4C ). Moreover, the arcuate sidewall members  512   a,b  may each be movably or compliantly coupled to the inner surface of the outer shell  302  using one or more compliant devices  308 . As a result, each arcuate sidewall member  512   a,b  may be independent of the other and separately engageable on the outer surface of the mold  200  as the insulation enclosure  520  is dropped over the mold  200 . 
     The inner shell  304  may further include a top member  514  (shown in dashed and phantom lines). In some embodiments, the top member  514  may also exhibit a generally circular shape, as depicted, but may equally be ovular or any polygonal shape, without departing from the scope of the disclosure. The top member  514  may be movably or compliantly coupled to a top inner surface of the outer shell  302  with one or more compliant devices  308  (not shown for the top member  514 ). Moreover, while not specifically labeled, the top member  514  may be a composite structure made of a support member  310  ( FIGS. 3 and 4A-4C ) and insulation material  312  ( FIGS. 3 and 4A-4C ). 
     Similar to the insulation enclosure  520 ,  FIG. 5D  also depicts an exemplary insulation enclosure  530  that exhibits a substantially circular horizontal cross-sectional shape. The inner shell  304  may include the top member  514 , but may further include four arcuate sidewall members  516  (shown as sidewall members  516   a ,  516   b ,  516   c , and  516   d ). While not specifically labeled, each arcuate sidewall member  516   a - d  may be a composite structure made of a support member  310  ( FIGS. 3 and 4A-4C ) and insulation material  312  ( FIGS. 3 and 4A-4C ). Moreover, the sidewall members  516   a - d  may each be movably or compliantly coupled to the inner surface of the outer shell  302  using one or more compliant devices  308 . As a result, each arcuate sidewall member  516   a - d  may be independent of the other sidewall members  516   a - d  and separately engageable on adjacent outer surfaces of the mold  200  as the insulation enclosure  530  is dropped over the mold  200 . 
     In  FIG. 5E , another exemplary insulation enclosure  540  is depicted as exhibiting a substantially circular horizontal cross-sectional shape. More particularly, the outer shell  302  may be circular and the inner shell  304  may also be circular in shape and include six arcuate sidewall members  520  (shown as sidewall members  520   a ,  520   b ,  520   c ,  520   d ,  520   e , and  520   f ). While not specifically labeled, each arcuate sidewall member  520   a - f  may be a composite structure made of a support member  310  ( FIGS. 3 and 4A-4C ) and insulation material  312  ( FIGS. 3 and 4A-4C ). Moreover, the arcuate sidewall members  520   a - f  may each be movably or compliantly coupled to the inner surface of the outer shell  302  using one or more compliant devices  308 . As a result, each arcuate sidewall member  520   a - f  may be independent of the other sidewall members  520   a - f  and separately engageable on the outer surface of the mold  200  as the insulation enclosure  540  is dropped over the mold  200 . 
     As illustrated, circumferentially adjacent sidewall members  520   a - f  may overlap each other a small distance to form an interleaved or nested relationship with one another. Such an interleaved relationship may prove advantageous in allowing the size (i.e., diameter) of the inner shell  304  to radially increase (or decrease) as the insulation enclosure  540  is dropped over the mold  200 . For example, upon encountering a mold  200  that exhibits a particular diameter, the sidewall member  520   a - f  may be able to slidingly engage each other and thereby increase the circumference of the inner shell  304  without exposing the sides of the mold  200 . Likewise, adjacent sidewall members  520   a - f  may also be able to slidingly engage each other to decrease the circumference of the inner shell  304  and thereby accommodate a mold  200  having a smaller size. 
     The inner shell  304  may further include a top member  522  (shown in dashed and phantom lines). In some embodiments, the top member  522  may also exhibit a generally circular shape, as depicted, but may equally be ovular or any polygonal shape, without departing from the scope of the disclosure. The top member  522  may be movably or compliantly coupled to a top inner surface of the outer shell  302  with one or more compliant devices  308  (not shown for the top member  522 ). Moreover, while not specifically labeled, the top member  522  may be a composite structure made of a support member  310  ( FIGS. 3 and 4A-4C ) and insulation material  312  ( FIGS. 3 and 4A-4C ). 
     Referring now to  FIGS. 6A-6C , with continued reference to  FIGS. 5A-5E , illustrated are cross-sectional top views of another exemplary insulation enclosure  600 , according to one or more embodiments. The insulation enclosure  600  may be similar to (or the same as) one or both of the insulation enclosures  300  and  400  described above with reference to  FIGS. 3 and 4A-4C  and therefore may be best understood with reference thereto, where like numerals will indicate like elements or components not described again. The mold  200  is again depicted as exhibiting a substantially circular cross-section, but may equally exhibit other cross-sectional shapes including, but not limited to, ovular, polygonal, polygonal with rounded corners, or any hybrid thereof. 
     The outer shell  302  may similarly exhibit a circular cross-sectional shape, and include four sidewall members  602  (shown as sidewall members  602   a ,  602   b ,  602   c , and  602   d ). Similar to the sidewall members  306   a,b  of  FIGS. 3 and 4A-4C , each sidewall member  602   a - d  may be a composite structure made of a support member  310  and insulation material  312 . The sidewall members  602   a - d  may each be movably or compliantly coupled to the inner wall/surface of the outer shell  302  using one or more compliant devices  308 . As a result, each sidewall member  602   a - d  may be independent of any adjacent sidewall member  602   a - d  and otherwise separately engageable on the outer surface of the mold  200  as the insulation enclosure  600  is dropped over the mold  200 . 
     The insulation material  312  in  FIGS. 6A-6C  may be selected such that it is compressible or deformable. As a result, the insulation material  312  may be reusable or otherwise employed for a one-time use. In  FIG. 6A , the compliant devices  308  are depicted in a retracted configuration so that the insulation material  312  of each sidewall member  602   a - d  is radially offset from the outer surfaces of the mold  200 . In  FIG. 6B , the compliant devices  308  are moved (e.g., actuated) to an expanded configuration and thereby urge the sidewall members  602   a - d  into physical engagement with the outer surfaces of the mold  200 . As the sidewall members  602   a - d  engage the mold  200 , the insulation material  312  may be configured to deform or otherwise crush against the outer surfaces of the mold  200 . As illustrated, the mold  200  is large enough that the crushable insulation material  312  deforms enough to enclose the mold  200  in a suitable minimum amount of insulation material  312 . In  FIG. 6C , the insulation enclosure  600  is depicted in use with a mold  200  that is smaller than the mold in  FIGS. 6A and 6B . The insulation material  312  in  FIG. 6C  deforms and completely encapsulates the mold  200  essentially out to the support members  310 . Accordingly, the insulation enclosure  600  may be used to potentially accommodate a wide range of mold  200  sizes. 
     Embodiments disclosed herein include: 
     An insulation enclosure that includes an outer shell having an open end and a top end, an inner shell arranged within the outer shell and including a plurality of sidewall members and a top member, wherein each sidewall member is independently moveable relative to one another and to the top member, and wherein the plurality of sidewall members and the top member each include a support member and insulation material positioned on the support member, and one or more compliant devices arranged between the outer shell and at least one of the plurality of sidewall members and the top member, the one or more compliant devices biasing the at least one of the plurality of sidewall members and the top member against adjacent outer surfaces of a mold disposable within the inner shell. 
     B. A method that includes removing a mold from a furnace, the mold having a top and a bottom, placing the mold on a thermal heat sink with the bottom adjacent the thermal heat sink, lowering an insulation enclosure around the mold, the insulation enclosure having an outer shell and an inner shell disposable within the outer shell and the inner shell including a plurality of sidewall members and a top member, wherein one or more compliant devices are arranged between the outer shell and at least one of the plurality of sidewall members and the top member, and wherein each sidewall member is independently moveable relative to one another and to the top member, engaging adjacent outer surfaces of the mold with the plurality of sidewall members and the top member, each sidewall and top member including a support member and insulation material positioned on the support member, and cooling the mold axially upward from the bottom to the top. 
     C. A method that includes introducing a drill bit into a wellbore, the drill bit being formed within a mold heated in a furnace and subsequently cooled, wherein cooling the drill bit comprises removing the mold from the furnace, the mold having a top and a bottom, and placing the mold on a thermal heat sink with the bottom adjacent the thermal heat sink, lowering an insulation enclosure around the mold, the insulation enclosure having an outer shell and an inner shell disposable within the outer shell and the inner shell including a plurality of sidewall members and a top member, wherein one or more compliant devices are arranged between the outer shell and at least one of the plurality of sidewall members and the top member, and wherein each sidewall member is independently moveable relative to one another and to the top member, engaging adjacent outer surfaces of the mold with the plurality of sidewall members and the top member, each sidewall and top member including a support member and insulation material positioned on the support member, and cooling the mold axially upward from the bottom to the top, and drilling a portion of the wellbore with the drill bit. 
     Each of embodiments A, B, and C may have one or more of the following additional elements in any combination: Element 1: wherein the outer shell comprises an outer frame, an inner frame, and insulation material positioned between the inner and outer frames. Element 2: wherein the one or more compliant devices are at least one of a spring and an actuation device. Element 3: wherein the insulation material is a material selected from the group consisting of ceramics, ceramic fibers, ceramic fabrics, ceramic wools, ceramic beads, ceramic blocks, moldable ceramics, woven ceramics, cast ceramics, fire bricks, carbon fibers, graphite blocks, shaped graphite blocks, polymer beads, polymer fibers, polymer fabrics, nanocomposites, fluids in a jacket, metal fabrics, metal foams, metal wools, metal castings, any composite thereof, and any combination thereof. Element 4: further comprising a reflective coating positioned on an inner surface of one or more of the support members or on an inner surface of the outer shell. Element 5: further comprising an insulative coating positioned on at least one of an inner surface of one or more of the support members, and outer surface of one or more of the support members, and a surface of the outer shell. Element 6: wherein the support member of at least one of the plurality of sidewall members and the top member is positioned on an interior of the inner shell and the insulation material is positioned on an exterior of the inner shell. Element 7: wherein the support member of at least one of the plurality of sidewall members and the top member is positioned on an exterior of the inner shell and the insulation material is positioned on an interior of the inner shell. Element 8: wherein the support member for at least one of the plurality of sidewall members and the top member includes a footing that extends horizontally from the support member. Element 9: wherein the support member for at least one of the plurality of sidewall members and the top member includes an inner support member and an outer support member offset from the inner support member, and wherein the insulation material is positioned between the inner and outer support members. Element 10: further comprising a thermal element in thermal communication with at least one of the top member and one or more of the plurality of sidewall members to impart thermal energy to the mold. Element 11: wherein the thermal element comprising an element selected from the group consisting of a heating element, a heat exchanger, a radiant heater, an electric heater, an infrared heater, an induction heater, a heating band, heated coils, heated fluids (flowing or static), an exothermic chemical reaction, or any combination thereof. Element 12: wherein at least one of the plurality of sidewall members includes multiple sidewall segments stacked atop one another, each sidewall segment being movably coupled to the adjacent inner surface of the outer shell with the one or more compliant devices. Element 13: wherein a thermal resistance of the multiple sidewall segments increases from a bottom of the inner shell toward a top of the inner shell. Element 14: wherein a horizontal cross-sectional shape of at least one of the inner and outer shells is polygonal, circular, or ovular. Element 15: wherein the plurality of sidewall members are arcuate. Element 16: wherein adjacent sidewall members of the plurality of sidewall members are interleaved and slidingly engageable with one another when the inner shell radially expands or radially contracts. 
     Element 17: wherein engaging adjacent outer surfaces of the mold with the plurality of sidewall members and the top member comprises expanding the plurality of sidewall members and the top member outward to accommodate the mold, and biasing the plurality of sidewall members and the top member against the adjacent outer surfaces of the mold with the one or more compliant devices. Element 18: wherein at least one of the one or more compliant devices is an actuation device, the method further comprising actuating the actuation device to urge a corresponding one or more of the plurality of sidewall members and the top member into engagement with the adjacent outer surfaces of the mold. Element 19: wherein the plurality of sidewall members are arcuate and adjacent sidewall members of the plurality of sidewall members are interleaved, the method further comprising slidingly engaging the adjacent sidewall members with one another as the inner shell radially expands or radially contracts to engage the adjacent outer surfaces of the mold. Element 20: cooling the mold by conduction with the plurality of sidewall members and the top member engaged with the adjacent outer surfaces of the mold. Element 21: further comprising imparting thermal energy to the top of the mold with a thermal element in thermal communication with the top member, the thermal element comprising an element selected from the group consisting of a heating element, a heat exchanger, a radiant heater, an electric heater, an infrared heater, an induction heater, a heating band, heated coils, heated fluids (flowing or static), an exothermic chemical reaction, or any combination thereof. Element 22: further comprising drawing thermal energy from the bottom of the mold with the thermal heat sink. Element 23: wherein at least one of the plurality of sidewall members includes multiple sidewall segments stacked atop one another, each sidewall segment being movably coupled to the adjacent inner surface of the outer shell with the one or more compliant devices, the method further comprising increasing a thermal resistance of the multiple sidewall segments from a bottom of the inner shell toward a top of the inner shell. 
     Therefore, the disclosed systems and methods are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the teachings of the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered, combined, or modified and all such variations are considered within the scope of the present disclosure. The systems and methods illustratively disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein. While compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted. 
     As used herein, the phrase “at least one of” preceding a series of items, with the terms “and” or “or” to separate any of the items, modifies the list as a whole, rather than each member of the list (i.e., each item). The phrase “at least one of” allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, the phrases “at least one of A, B, and C” or “at least one of A, B, or C” each refer to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.