Patent ID: 7585366

Claim:
A method for controlling nucleation sites during superabrasive particle synthesis, comprising the steps of: a) forming a particulate crystal growth layer, including a substantially homogeneous mixture of raw material and catalyst material; b) placing crystalline seeds in a predetermined pattern at least partially in the particulate crystal growth layer to form a growth precursor; and c) heating and pressing the growth precursor to a temperature and pressure sufficient for growth of superabrasive particles to produce grown superabrasive particles; wherein the step of placing crystalline seeds includes the steps of: a) placing a template having a pattern of apertures upon a surface of the crystal growth layer, each of said apertures being configured to receive a single crystalline seed; b) filling the apertures of said template with the crystalline seeds; and c) pressing said crystalline seeds at least partially into the crystal growth layer; or wherein the step of placing crystalline seeds includes the steps of: d) providing a transfer sheet having an adhesive layer thereon; e) placing a template having a pattern of apertures upon the adhesive layer, each of said apertures being configured to receive a single crystalline seed; f) filling the apertures of said template with the crystalline seeds; g) placing the transfer sheet against a surface of the crystal growth layer; and h) pressing said crystalline seeds at least partially into the crystal growth layer; or wherein the step of placing crystalline seeds includes the steps of: i) providing a vacuum chuck configured with a pattern of apertures; j) pulling a vacuum through the apertures and engaging a single crystalline seed in each aperture; k) depositing the crystalline seeds on a surface of the crystal growth layer such that the crystalline seeds are arranged in a predetermined pattern corresponding to the pattern of apertures; and l) pressing said crystalline seeds at least partially into the crystal growth layer.