# US 11,667,011 B2 · Methods of making a polycrystalline diamond structure > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,667,011 B2 - Document ID: US11667011B2 - Status: Granted - Kind: B2 - Application number: 16/381,274 - Filed: 2019-04-11 - Published: 2019-08-01 - Granted: 2023-06-06 - Earliest claimed: 2014-08-19 - Assignees: US Synthetic Corporation - Applicants: US Synthetic Corporation - Inventors: David P. Miess - Web page: https://patentgrep.com/patent/US11667011B2 ## CPC - B24D 18/0009: {using moulds or presses} - B22F 3/14: simultaneously - B22F 5/085: {with helical contours} - B22F 7/06: of composite workpieces or articles from parts, e.g. to form tipped tools {(B22F7/002 takes precedence)} - B23C 5/10: Shank-type cutters, i.e. with an integral shaft - B23G 5/06: Taps (chucks therefor B23B31/00) - B24D 99/005: {Segments of abrasive wheels} - C22C 26/00: Alloys containing diamond {or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes} - E21B 10/573: characterised by support details, e.g. the substrate construction or the interface between the substrate and the cutting element - B22F 2005/001: {Cutting tools, earth boring or grinding tool other than table ware} - B23B 51/00: Tools for drilling machines - B23B 2226/315: polycrystalline [PCD] - B23C 2226/315: polycrystalline [PCD] - B23G 2225/165: Polycrystalline diamond - B24D: TOOLS FOR GRINDING, BUFFING OR SHARPENING (abrading-bodies specially designed for tumbling apparatus, e.g. abrading-balls B24B31/14; honing tools B24B33/08; lapping tools B24B37/11) - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B23C: MILLING (broaching B23D; broach-milling in making gears B23F; arrangement for copying or controlling B23Q) - B23G: THREAD CUTTING; WORKING OF SCREWS, BOLT HEADS, OR NUTS, IN CONJUNCTION THEREWITH (making helical grooves by turning B23B5/48, by milling B23C3/32, by forging, pressing, or hammering B21K1/56, by grinding B24B19/02; arrangements for copying or controlling B23Q; thread-forming by corrugating tubes B21D15/04, by rolling B21H3/02) - C22C: ALLOYS (treatment of alloys C21D, C22F) - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS - B23B: TURNING; BORING (arrangements for copying or controlling B23Q) ## Abstract Embodiments of the invention relate to methods of making articles having portions of polycrystalline diamond bonded to a surface of a substrate and polycrystalline diamond compacts made using the same. In an embodiment, a molding technique is disclosed for forming cutting tools comprising polycrystalline diamond portions bonded to the outer surface of a substrate. ## Claims ### Claim 1 A method of making a polycrystalline diamond (“PCD”) structure having a substrate and at least one PCD portion, the method comprising: providing a can formed at least partially by three-dimensional (3-D) printing; positioning the substrate and diamond particles within the can; and subjecting the substrate and the diamond particles positioned within the can to a high-pressures/high-temperature (“HPHT”) process effective to sinter the diamond particles and bond the at least one PCD portion at least partially formed from the diamond particles to a portion of the substrate. ### Claim 2 (depends on 1) The method of claim 1, wherein providing a can formed at least partially by 3-D printing includes 3-D printing the can. ### Claim 3 (depends on 2) The method of claim 2, wherein: 3-D printing the can includes 3-D printing a wall at least partially defining a cavity, the cavity having a cylindrical portion and at least one flute recess in the wall; and positioning the substrate and diamond particles within the cavity includes positioning the substrate within the cylindrical portion of the cavity and positioning the diamond particles within the at least one flute recess. ### Claim 4 (depends on 2) The method of claim 2, wherein 3-D printing the can includes 3-D printing a metal can having an average wall thickness of about 0.003 inches to about 0.02 inches. ### Claim 5 (depends on 4) The method of claim 4, wherein 3-D printing the metal can includes 3-D printing a titanium alloy metal can having an average wall thickness of about 0.011 inches to about 0.015 inches. ### Claim 6 (depends on 1) The method of claim 1, wherein positioning the substrate and diamond particles within the can includes positioning the substrate and at least one diamond material flute volume including at least one diamond material tube having the diamond particles with the at least one diamond material tube in contact with a portion of the surface of the substrate. ### Claim 7 (depends on 6) The method of claim 6, further comprising attaching at least one portion of the at least one diamond material flute volume to the substrate using at least one of induction heating, laser tacking adhesive, or a binder material. ### Claim 8 (depends on 6) The method of claim 6, wherein the at least one diamond material tube includes a cobalt-containing tube. ### Claim 9 (depends on 6) The method of claim 6, wherein the at least one diamond material flute volume includes a plurality of shear compacted diamond particles. ### Claim 10 (depends on 6) The method of claim 6, wherein positioning the at least one diamond material flute volume includes positioning at least one preformed diamond volume generally helically around at least a portion of the substrate. ### Claim 11 (depends on 6) The method of claim 6, further comprising: processing the at least one diamond flute volume using at least one of milling, grinding, lapping, electro-discharge machining, or lasing; and at least partially leaching the at least one diamond flute volume to a selected depth therein.