Abstract: Based on the principle of finite life design, the influencing factors on the fracture resistance and fatigue life of drill rod are analyzed according to wave mechanics and dynamics of percussive drilling. A thin-wall tubular drill rod is thus suggested to improve its fracture resistance by low stress distribution. With the purpose of no extra consumption of drill steel but improving the fracture resistance of drill rod by reducing its cyclic stress, the outer diameter of drill rod is remarkably increased. The fatigue life of the newly developed drill rod is also predicted according to the S-N curve of drill steel and its theoretical loading spectrum. Industrial test indicates that the fatigue life of the thin-wall tubular rod is up to 1200 m, near 70% higher than that of domestic conventional products.