Abrasive coating and method of manufacturing same

A method of manufacturing an individual casting mold for use in the manufacture of a structured abrasive coating on an individual abrasive product, comprising the steps of:

• a.) identifying at least one processing area on an upper side of the casting mold, which is used for shaping the individual abrasive product, wherein the upper side has the shape of a specially desired tool;
• b.) creating a three-dimensional product specific molding pattern, within said processing area, wherein the pattern is made of a plurality of prototypes used to form individual composite grains, by
• dividing said processing area by forming a box field applying a grid of generally transverse axes to identify a grid of composite fields further divided into receiving individual boxes for prototypes,
• distributing said prototypes in a mathematically random manner within each individual box, and
• repeating the distribution of prototypes for composites grains in each individual box placed in each processing area identified according to step a);
• c. to finally complete a male mold of the entire abrasive surface for manufacturing an intermediate female mold of the entire abrasive surface simultaneously for said manufacture of the structured abrasive coating of an individual abrasive product;
• said mold making it possible to reproduce multiple structured abrasive products from a mold.

A method of manufacturing an individual casting mold for use in making an intermediary mold which then may be used in the an individual abrasive product manufacture having a structured abrasive coating, comprising the steps of:

• a.) creating a model for the upper surface of the casting mold comprising at least one processing area;
• b.) dividing at least one processing areas into composite fields bound by intersecting axes;
• c.) mathematically generating a plurality of random coordinates for placement of prototypes for abrasive composites;
• d.) in the model, placing the prototypes for abrasive composites at locations corresponding to the random coordinates, the coordinates lying within at least one processing area;
• and
• e.) creating the casting mold having said prototypes placed in said random locations of the entire abrasive surface of a desired tool;
• whereby the pattern formed by the prototypes locations on the mold are random with respect to each individual box thereof, but that substantially every individual box has at least one prototype of composite applied therewithin.