Patent ID: 7658666

Claim:
A method of forming a cutting device, comprising: arranging a plurality of individual polycrystalline cutting elements in an uncured organic material, each of the plurality of individual polycrystalline cutting elements having a substantially matching, wedge-shaped geometric configuration and a longitudinal axis extending from a base of the wedge-shaped geometric configuration toward an apex of the wedge-shaped geometric configuration; orienting at least some of the wedge-shaped cutting elements such that a longitudinal axis of each of the at least some cutting elements is aligned along, and is collinear with, a radius of the cutting device, and a wider portion of each of the at least some cutting elements is disposed nearer an outer perimeter of the cutting device than is a narrower portion of each of the at least some cutting elements; and curing the organic material to form a solidified organic material layer, such that each of the plurality of individual polycrystalline cutting elements is secured therein.