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Overview of Industrial Diamond Manufacturing

Apr 4, 2025

Lecture Notes: Industrial Diamond Manufacturing at US Synthetic

Introduction

  • Location: US Synthetic, one of the largest industrial diamond manufacturing facilities.
  • Focus: Manufacturing genuine Mohs 10 level polycrystalline black diamonds.
  • 99% of diamonds used annually are synthetic industrial diamonds.
  • Applications include drilling, frictionless bearings, and maintenance-free electricity generation.

Manufacturing Process

Ingredients and Preparations

  • Ingredients: Monolithic diamond polishing powder, cobalt from cobalt-cemented tungsten carbide.
  • Process:
    • Diamond dust placed in a small metal thimble.
    • Cobalt acts as a substrate for diamond creation.

Creating the Diamonds

  • Heater Cylinder:

    • Metal cylinder used to create two diamonds at a time.
    • Filled with clean white table salt to center diamond molds.
    • Salt and talc blocks formed as supports.
  • Six-Piston Cubic Diamond Press:

    • Focuses over 1 million PSI onto diamond mold.
    • Press is housed in blast rooms due to high pressure and potential hazards.

Heat and Pressure Application

  • Heating Element:
    • Circular positive and negative contact pads heat the metal canister to 2500°F.
    • Heat crystallizes diamond dust and liquifies cobalt.

Formation of Polycrystalline Black Diamonds

  • Process:
    • Cobalt leaches into diamond catalyzing crystal formation.
    • Results in tougher synthetic diamonds than natural ones.

Cleanup and Final Steps

  • Cleanup:

    • Utilizes non-toxic salt and talc.
    • Uses silicon carbide sandblaster to remove casings.
  • Polishing and Uses:

    • CNC polishing machines finish the diamonds to correct dimensions.
    • Tungsten carbide base can be used as a mounting location or removed.
    • Applications include high-end 3D printer nozzles.

Applications and Hardness Testing

  • 3D Printing:

    • Diamond 3D printer tips are extraordinarily durable.
    • Resistant to wear from abrasive filaments.
  • Hardness Test:

    • Demonstrated using Mohs hardness picks.
    • Polycrystalline diamonds withstand level 9 hardness tests.

Conclusion

  • The potential for further uses of diamonds in technology and manufacturing.
  • Inquiry into possible future applications, like a diamond phone case.
  • Appreciation for the tour and exploration of industrial diamond capabilities.