Abstract: Systems and methods of forming components from CVD single crystal diamonds that can withstand high temperatures and pressures, for example, in a mining and/or drilling environment. This may be accomplished by transforming a graphite powder by hot-filament chemical vapor deposition (HFCVD) into a CVD single diamond crystal powder, growing a plurality of CVD single diamond crystals on a planar surface of a substrate or on a dowel. In one example, if a substrate is used as the growth surface, the plurality of CVD single crystals grow in at least one layer on the substrate and at least a portion of the plurality of CVD single diamond crystals are removed from the substrate in the form of a plurality of discrete intact sheets of CVD single diamond crystals, stacked in a mold, and sintered, for example, to form a CVD single crystal diamond table.

Abstract: Systems and methods of forming components from CVD single crystal diamonds that can withstand high temperatures and pressures, for example, in a mining and/or drilling environment. This may be accomplished by transforming a graphite powder by hot-filament chemical vapor deposition (HFCVD) into a CVD single diamond crystal powder, growing a plurality of CVD single diamond crystals on a planar surface of a substrate or on a dowel. In one example, if a substrate is used as the growth surface, the plurality of CVD single crystals grow in at least one layer on the substrate and at least a portion of the plurality of CVD single diamond crystals are removed from the substrate in the form of a plurality of discrete intact sheets of CVD single diamond crystals, stacked in a mold, and sintered, for example, to form a CVD single crystal diamond table.

Abstract: A precise and reproducible method of making a cutter element for a cutting tool includes positioning at least a first material layer of powder; a substrate and sintering. Whereby the positioning is performed by a fill to weight system, and comprises depositing the first material at a rate of about 1 mg per second to about 300 mg per second by the automated system.

Abstract: A rolling cutter drill bit comprises a body and three legs, each leg having a cantilevered bearing spindle, a rolling cutter rotatably mounted on the bearing spindle, lubricant delivering means within the bearing spindle, and a floating thrust bearing element configured to carry onward thrust loads from the rolling cutter onto the bearing spindle. Each floating thrust bearing element is formed of a wrought alloy material consisting primarily of chromium carbide and cobalt and having a yield strength of less than 120,000 psi and a ductility of at least 4%, both at room temperature.

Abstract: A rolling cutter drill bit comprises a body and three legs, each leg having a cantilevered bearing spindle, a rolling cutter rotatably mounted on the bearing spindle, lubricant delivering means within the beating spindle, and a floating thrust bearing element configured to carry onward thrust loads from the rolling cutter onto the bearing spindle. Each floating thrust bearing element is formed of a wrought alloy material consisting primarily of chromium carbide and cobalt and having a yield strength of less than 120,000 psi and a ductility of at least 4%, both at room temperature.