Abstract: In some embodiments, a cutting system including a movable blade operably coupled to a motor is disclosed, wherein the cutting system comprises a diverting feature. In some embodiments, a diverter proximity relative to the movable blade is selected to facilitate diversion of a material during cutting. In at least one embodiment, the movable blade may be a circular blade or a reciprocating blade with a thickness of less than 3/32 of an inch. A cutting system according to the present invention may be coupled to a container, for example, a residential trash container or a residential recycling container.

Abstract: In some embodiments, a cutting system including a movable blade or a reciprocating blade operably coupled to a motor is disclosed, wherein the cutting system comprises a diverting feature. In some embodiments, a diverter proximity relative to the movable blade or reciprocating blade is selected to facilitate diversion of a material during cutting. In at least one embodiment, the movable blade may be movable blade for an oscillating tool. A cutting system according to the present invention may be coupled to a container, for example, a residential trash container or a residential recycling container.

Abstract: In some embodiments, a cutting system including a movable blade operably coupled to a motor is disclosed, wherein the cutting system comprises a diverting feature. In some embodiments, a diverter proximity relative to the movable blade is selected to facilitate diversion of a material during cutting. In at least one embodiment, the movable blade may be a circular blade or a reciprocating blade with a thickness of less than 3/32 of an inch. A cutting system according to the present invention may be coupled to a container, for example, a residential trash container or a residential recycling container.

Abstract: The residual stresses that are experienced in polycrystalline diamond cutters, which lead to cutter failure, can be effectively modified by selectively thinning the carbide substrate subsequent to high temperature, high pressure (sinter) processing, by selectively varying the material constituents of the carbide substrate, by subjecting the PDC cutter to an annealing process during sintering, by subjecting the formed PDC cutter to a post-process stress relief anneal, or a combination of those means.

Abstract: A method of fabricating the drill bit includes employing known layered-manufacturing techniques to fabricate the bit crown, positioning a bit gage mold adjacent the bit crown, and disposing a core material within an interior of the bit crown and a cavity of the bit gage mold. A mold that may be employed to fabricate the drill bit includes an initially conforming mold region, in which the prefabricated bit crown may be disposed, and a second, substantially rigid mold region including a cavity to define the gage of the drill bit. Preferably, the conforming mold region is formed of a nonwettable, granular material.

Abstract: A method of infiltrating preformed, bonded-particulate components, such as rotary bits, for subterranean drilling manufactured by techniques such as layered-manufacturing or those employed in rapid prototyping technology. A support structure is provided for the preformed component to physically support the preformed component during various manufacturing processes such as sintering and infiltration.

Abstract: The residual stresses that are experienced in polycrystalline diamond cutters, which lead to cutter failure, can be effectively modified by selectively thinning the carbide substrate subsequent to high temperature, high pressure (sinter) processing, by selectively varying the material constituents of the carbide substrate, by subjecting the PDC cutter to an annealing process during sintering, by subjecting the formed PDC cutter to a post-process stress relief anneal, or a combination of those means.

Abstract: The residual stresses that are experienced in polycrystalline diamond cutters, which lead to cutter failure, can be effectively modified by selectively thinning the carbid substrate subsequent to a high-temperature, high-pressure (sinter) processing, by selectively varying the material constituents of the carbide substrate, by subjecting the PDC cutter to an annealing process during sintering, by subjecting the formed PDC cutter to a post-process stress relief anneal, or by a combination of those means.

Abstract: A rotary-type earth-boring drill bit including a layer-manufactured, substantially hollow bit crown and an integral bit interior and bit gage. The bit interior and bit gage may be formed of a particulate material infiltrated with an infiltrant material. A particulate material of the bit crown may be integrally infiltrated with the particulate material of the bit interior and bit gage. Alternatively, the bit interior and bit gage may comprise a single cast material. The particulate material of the bit crown may be infiltrated with the cast material of the bit interior and bit gage. A method of fabricating the drill bit of the present invention includes employing known layered-manufacturing techniques to fabricate the bit crown, positioning a bit gage mold adjacent the bit crown, and disposing a core material within an interior of the bit crown and a cavity of the bit gage mold.

Abstract: A rotary-type earth-boring drill bit including a layer-manufactured, substantially hollow bit crown and an integral bit interior and bit gage. The bit interior and bit gage may be formed of a particulate material infiltrated with an infiltrant material. A particulate material of the bit crown may be integrally infiltrated with the particulate material of the bit interior and bit gage. Alternatively, the bit interior and bit gage may comprise a single cast material. The particulate material of the bit crown may be infiltrated with the cast material of the bit interior and bit gage. A method of fabricating the drill bit includes employing known layered-manufacturing techniques to fabricate the bit crown, positioning a bit gage mold adjacent the bit crown, and disposing a core material within an interior of the bit crown and a cavity of the bit gage mold.

Abstract: A method of infiltrating preformed, bonded-particulate components, such as rotary bits, for subterranean drilling manufactured by techniques such as layered-manufacturing or those employed in rapid prototyping technology. A support structure is provided for the preformed component to physically support the preformed component during various manufacturing processes such as sintering and infiltration.

Abstract: A method of infiltrating preformed, bonded-particulate components, such as rotary bits, for subterranean drilling manufactured by techniques such as layered-manufacturing or those employed in rapid prototyping technology. A support structure is provided for the preformed component to physically support the preformed component during various manufacturing processes such as sintering and infiltration.

Abstract: A method of manufacturing a bit body, other drilling-related component, or other article of manufacture, including fabricating a particulate-based matrix and infiltrating the particulate-based matrix with a binder that includes cobalt or iron. The binder may be a cobalt alloy or an iron alloy. The particulate-based matrix may be disposed within a non-graphite mold. The particulate-based matrix and binder are placed within an induction coil and an alternating current is applied to the induction coil in order to directly heat the binder, permitting the binder to infiltrate or otherwise bind the particles of the matrix together. The molten binder may then be directionally cooled by forming a cooling zone around an end portion of the bit body and increasing the size of the cooling zone relative to the bit body.

Abstract: The residual stresses that are experienced in polycrystalline diamond cutters, which lead to cutter failure, can be effectively modified by selectively thinning the carbide substrate subsequent to high temperature, high pressure (sinter) processing, by selectively varying the material constituents of the cutter substrate, by subjecting the PDC cutter to an annealing process during sintering, by subjecting the formed PDC cutter to a post-process stress relief anneal, or a combination of those means.

Abstract: A method of fabricating rotary-type drill bits, drilling-related structures, and other articles of manufacture. The method includes fabricating a machinable matrix, machining the matrix, and dispersing a binder material throughout the matrix. The matrix of the rotary-type drill bit may be fabricated by layered-manufacturing techniques or by disposing a particulate or powdered material into a mold and binding the particles together with a resin or by sintering. The matrix may have the desired dimensions and features, the approximate dimensions and features, or lack desired dimensions or features of a drilling-related structure or other article of manufacture. The matrix is machined to correct any anisotropies or imperfections of the matrix, to refine features of the matrix, or to define the features in the matrix. The machined matrix may be infiltrated with a binder material to define a drill bit body.

Abstract: A method of altering the force balance characteristic or moment configuration of an earth-boring rotary-type drill bit by altering the net hydraulic direction vector of drilling fluid exiting from the drill bit and, therefore, the accompanying net hydraulic force exerted on the drill bit. The method includes replacing at least one nozzle of the drill bit with a differently sized nozzle to alter the amount of hydraulic force that is exerted on a particular portion of the drill bit. Alternatively, the orientation of at least one nozzle of the drill bit may be changed to alter the direction in which drilling fluid flows from a particular portion of the drill bit and, thus, alter the direction of the hydraulic force on the drill bit. The method may be employed to counteract a net force imbalance of a drill bit, to alter a direction of net force imbalance, or to vary the magnitude of net force imbalance.

Abstract: A superhard cutting element having a polished, low friction, substantially planar cutting face with a surface finish roughness of 10 .mu.in. or less and preferably 0.5 .mu.in. or less. A chamfered cutting edge and side surface of the superhard material table of the same surface finish roughness are also disclosed. The surface roughness of the aforementioned superhard material table portions may be reduced by mechanically smoothing and polishing according to one of several variations of the method of the invention.

Abstract: A cutter for use on a rotary-type drag bit for earth boring is provided comprising a substantially rectangular diamond table attached to a substrate. At least one elongated support structure made of polycrystalline diamond is contained in the cutting substrate and extends from the cutting edge of the diamond table and into the substrate. The support structure is generally arranged in line with a predicted drilling force vector that will be applied to the cutting element during drilling. The support structure, in addition to or in lieu of providing support for the cutting element, may also serve to enhance heat transfer away from the cutting face and cutting edge of the superhard table.

Abstract: A superhard cutting element having a polished, low friction 1 substantially planar cutting face with a surface finish roughness of 10 .mu. in. or less and preferably 0.5 .mu. in. or less. A chamfered cutting edge and side surface of the superhard material table of the same surface finish roughness are also disclosed. The surface roughness of the aforementioned superhard material table portions may be reduced by mechanically smoothing and polishing according to one of several variations of the method of the invention.

Abstract: A method of infiltrating preformed, bonded-particulate components, such as rotary bits, for subterranean drilling manufactured by techniques such as layered-manufacturing or those employed in rapid prototyping technology. A support structure is provided for the preformed component to physically support the preformed component during various manufacturing processes such as sintering and infiltration.