Patent ID: 8758463

Claim:
A method for forming a cutting element, comprising: sintering diamond crystals and a catalyst material at high temperature and high pressure to form a polycrystalline diamond material body; removing at least a substantial portion of the catalyst material from the polycrystalline diamond material body to form a thermally stable polycrystalline diamond body; and bonding the thermally stable polycrystalline diamond body to a substrate, wherein bonding comprises: placing the thermally stable polycrystalline diamond body and the substrate into an enclosure, heating the thermally stable polycrystalline diamond body and the substrate to remove residual materials from the thermally stable polycrystalline diamond body; subjecting the thermally stable polycrystalline diamond body and the substrate to a vacuum for evacuating such residual materials; pressing the enclosure, the thermally stable polycrystalline diamond body and the substrate while maintaining a vacuum in said enclosure to bond the thermally stable polycrystalline diamond body to the substrate, wherein said thermally stable polycrystalline diamond body and said substrate are pressed at an elevated temperature; and preventing contact of said thermally stable polycrystalline diamond body with the enclosure during pressing.