Abstract: The present disclosure relates to methods of laser-leaching polycrystalline diamond (PCD), devices for performing such methods, and to laser-leached PCD and elements and drill bits containing laser-leached PCD.

Abstract: A mold transfer assembly includes a transfer housing providing an interior defined by one or more sidewalls and a top. The transfer housing is sized to receive and encapsulate a mold as the mold is moved between a furnace and a thermal heat sink. An arm is coupled to the transfer housing to move the transfer housing and the mold encapsulated within the transfer housing between the furnace and a thermal heat sink. The transfer housing exhibits one or more thermal properties to control a thermal profile of the mold.

Abstract: There is disclosed herein a method of designing a mold, the mold being at least part of a unitary body to be formed from a plurality of layers by 3D printing, the method comprising: defining an inner surface of the mold corresponding to at least part of an outer surface of an object to be molded in the mold; selecting a first material from which at least part of the mold is to be printed; and selecting a second material from which at least another part of the mold is to be printed, the second material having a higher thermal and/or electrical conductivity than the first material, wherein at least one of the layers from which the mold is to be formed by 3D printing includes areas to be printed from each of the first and second materials.

Abstract: Cutting elements and other hardfacing components of a drill bit or other downhole equipment are provided that include a thermally stable polycrystalline material anodically bonded to a substrate. Methods and systems for making such elements and components are also provided.

Abstract: A method of manufacturing a rotary drill bit includes forming a mold having an inner surface and an outer surface, locating a metal mandrel within the mold, packing the mold around at least part of the mandrel with particulate matrix-forming material and installing an insulating material around at least an upper portion of the outer surface. The material is infiltrated in a furnace with a molten binding alloy and the mold including the insulating material is removed from the furnace, directionally solidifying the material and binding alloy in portion of said bit, wherein said directional solidification proceeds from the lower portion of the outer surface in an upward and outward direction to form a solid infiltrated matrix bonded to the mandrel by cooling of the mold with the insulating material disposed around at least the upper portion of the outer surface of the mold.

Abstract: There is disclosed herein a method of designing a mold, the mold being at least part of a unitary body to be formed from a plurality of layers by 3D printing, the method comprising: defining an inner surface of the mold corresponding to at least part of an outer surface of an object to be molded in the mold; selecting a first material from which at least part of the mold is to be printed; and selecting a second material from which at least another part of the mold is to be printed, the second material having a higher thermal and/or electrical conductivity than the first material, wherein at least one of the layers from which the mold is to be formed by 3D printing includes areas to be printed from each of the first and second materials.

Abstract: There is disclosed herein a method of printing a printed body to be formed from a plurality of layers by 3D printing, the method comprising: depositing a plurality of layers of material, the material in the layers being bonded to form a body from the layers, the body including a mold that at least partially defines a mold cavity having an inner surface substantially corresponding to at least a portion of the external surface of an object to be molded in the mold cavity, wherein: the object to be molded is to be formed by infiltrating a matrix material held in the mold cavity with an infiltration material; and the body includes at least a portion of the matrix material to be held in the mold cavity, the at least a portion of the matrix material being deposited and bonded in the plurality of layers during printing of the body.

Abstract: There is disclosed herein a method of designing a mold assembly including a container (300) and a mold (200), at least portions of an outer surface of the mold corresponding to an inner surface of the container such that the container will support the mold therein, in use of the mold for molding an object, the mold assembly defining a mold cavity (252) substantially corresponding to the outer shape of the object to be molded, wherein one or more portions of the mold cavity are defined by the inner surface of the container.

Abstract: There is disclosed herein a method of molding an object by infiltrating a matrix material with an infiltration material, the method including providing first and second zones of respective different first and second matrix materials arranged substantially adjacent to each other in a mold, including forming a transition region between the two zones through which the composition of the material in the transition region is gradually varied from the composition of the first matrix material adjacent the first zone to the composition of the second matrix material near the second zone.