Patent ID: 8573332

Claim:
A method of forming a polycrystalline diamond element, the method comprising: forming a polycrystalline diamond compact from diamond particles at a temperature and a pressure sufficient to form diamond-to-diamond bonds in the presence of a catalyst comprising one of a Group VIII element and an alloy thereof; substantially removing the catalyst from the polycrystalline diamond compact; and securing the polycrystalline diamond compact having the catalyst substantially removed therefrom to a supporting substrate at a temperature and a pressure sufficient to maintain stability of diamond-to-diamond bonds in the polycrystalline diamond compact in the presence of a binder material differing at least in part from a material of the catalyst and comprising one of a Group VIII element and an alloy thereof, and to introduce the binder material into interstitial voids between diamond particles of the polycrystalline diamond compact and substantially fill the polycrystalline diamond compact with the binder material.