Abrasive element precursor with precisely shaped features and methods of making thereof

A method of making an abrasive element precursor comprising:

• providing a mold having a plurality of precisely shaped cavities;
• providing a mixture comprising a plurality of inorganic particles, a binder, and a carbon source, wherein the mixture is in the form of spray dried agglomerates and wherein the plurality of inorganic particles are at least about 99% carbide ceramic by weight;
• and
• forming a green body ceramic element having first and second major surfaces, wherein at least the first major surface comprises a plurality of precisely shaped features, and wherein the green body ceramic element comprises a plurality of inorganic particles, a binder, and a carbon source, wherein the plurality of inorganic particles are at least about 99% carbide ceramic by weight, and wherein the binder is a thermoplastic with a Tg of less than about 25° C.;
• wherein forming the green body ceramic element further comprises filling a majority of the cavities with the mixture.

A method of forming an abrasive element comprising:

• providing a mold having a plurality of precisely shaped cavities;
• providing a mixture comprising a plurality of inorganic particles, a binder, and a carbon source, wherein the mixture is in the form of spray dried agglomerates and wherein the plurality of inorganic particles are at least about 99% carbide ceramic by weight;
• forming a green body ceramic element having first and second major surfaces, wherein at least the first major surface comprises a plurality of precisely shaped features, wherein the green body ceramic element comprises a plurality of inorganic particles, a binder, and a carbon source, wherein the plurality of inorganic particles are at least about 99% carbide ceramic by weight, based on the total weight of the mixture, wherein the binder is a thermoplastic with a Tg of less than about 25° C., and wherein forming the green body ceramic element further comprises filling a majority of the cavities with the mixture;
• removing the green body ceramic element from the mold;
• and
• heating the green body ceramic element to cause sintering of the inorganic particles.

An abrasive element precursor comprising:

• a green body ceramic element having a first major surface and a second major surface;
• wherein the green body ceramic element includes a plurality of inorganic particles, a binder and a carbon source and wherein the plurality of inorganic particles, the binder and the carbon source form a mixture in the form of a dried ceramic-binder powder;
• wherein at least the first major surface comprises a plurality of precisely shaped features;
• wherein the plurality of inorganic particles are at least about 99% carbide ceramic by weight;
• and
• wherein the inorganic particles comprise at least about 90% silicon carbide by weight.