The document discusses fabrication technologies for complex shaped diamond tools using powder injection moulding (DIM), including its advantages over traditional methods. DIM allows fabrication of tools with intricate geometries not previously possible. It involves mixing diamond powder with temporary and backbone binders, injection moulding, debinding, and sintering. DIM provides higher yields than traditional bead production, with no reassembly needed. Further improvements to DIM include developing new powder varieties and equipment for granulation and moulding.

1. Fabrication of Complex Shaped Diamond Tools Via Powder Injection Moulding PM2010 WORLD CONGRESS Florence, 10-14 October 2010

3. Traditional Technologies Electroplating Hot pressing

4. Sintering furnaces set Traditional Technologies Hot isostatic pressing

5. Powder Binder Feedstock DIM

6. Injection Moulding

7. Debinding Metal Powder Temporary binder Backbone binder

8. Pressureless sintering

9. DIM MATERIALS Typical Volume loading Typical Viscosity (Pa*s) 100°C 100 s -1 Sintering temperature Typical final density Cobalt 45-50% 150-160 850-950°C 98% Cobalt/WC 44-47% 170-180 950-1000°C 93-97% Cobalt/Bronze 44-60% <100 840-900°C >98% Cobalt/Iron 45-50% 150-160 900-950°C 97% Cobalt/Iron Bronze 45-50% 120-130 850-950°C 93-97% NEXT 400 45-50% 230-250 900-950°C 97-98%

10. Equipments: Granulation and Moulding Still to improve Powders: Variety and Grades Research: Modelling

31. MATERIALS Class Block Length Block Height SLATE m 2 FEED cm/h Vs m/sec Brown Chocolate 4 287 187 5,37 16 29 Kashmir Gold 1 344 198 6,81 35 31 New Bengal Black 3 312 190 5,93 20 29 Emerald Pearl 1 335 187 6,26 26 28 Absolute Black 3 337 140 4,72 20 29 Vizag Blue 2 277 204 5,65 35 30