The method generally involves the steps of filling the cavities in a production tool each with an individual abrasive particle. Aligning a filled production tool and a resin coated backing for transfer of the abrasive particles to the resin coated backing. Transferring the abrasive particles from the cavities onto the resin coated backing and removing the production tool from the aligned position with the resin coated backing. Thereafter the resin layer is cured, a size coat is applied and cured and the coated abrasive article is converted to sheet, disk, or belt form by suitable converting equipment.

Shaped ceramic abrasive particles include a first surface having a perimeter having a perimeter comprising at least first and second edges. A first region of the perimeter includes the second edge and extends inwardly and terminates at two corners defining first and second acute interior angles. The perimeter has at most four corners that define acute interior angles. A second surface is disposed opposite, and not contacting, the first surface. A peripheral surface is disposed between and connects the first and second surfaces. The peripheral surface has a first predetermined shape. Methods of making the shaped ceramic abrasive particles, and abrasive articles including them are also disclosed.

Shaped ceramic abrasive particles include a first surface having a perimeter having a perimeter comprising at least first and second edges. A first region of the perimeter includes the second edge and extends inwardly and terminates at two corners defining first and second acute interior angles. The perimeter has at most four corners that define acute interior angles. A second surface is disposed opposite, and not contacting, the first surface. A peripheral surface is disposed between and connects the first and second surfaces. The peripheral surface has a first predetermined shape. Methods of making the shaped ceramic abrasive particles, and abrasive articles including them are also disclosed.

A method of fabricating a polishing pad using an additive manufacturing system includes depositing a first set successive layers by droplet ejection to form a. Depositing the successive layers includes dispensing a polishing pad precursor to first regions corresponding to partitions of the polishing pad and dispensing a sacrificial material to second regions corresponding to grooves of the polishing pad. Removing the sacrificial material provides the polishing pad with a polishing surface that has the partitions separated by the grooves.

Embodiments of the present disclosure relate to advanced polishing pads with tunable chemical, material and structural properties, and new methods of manufacturing the same. According to one or more embodiments of the disclosure, it has been discovered that a polishing pad with improved properties may be produced by an additive manufacturing process, such as a three-dimensional (3D) printing process. Embodiments of the present disclosure thus may provide an advanced polishing pad that has discrete features and geometries, formed from at least two different materials that include functional polymers, functional oligomers, reactive diluents, and curing agents. For example, the advanced polishing pad may be formed from a plurality of polymeric layers, by the automated sequential deposition of at least one resin precursor composition followed by at least one curing step, wherein each layer may represent at least one polymer composition, and/or regions of different compositions.

An abrasive article includes a plurality of abrasive features disposed on one or more abrasive elements. Each of the one or more abrasive elements includes a base having a first major surface from which the plurality of abrasive features extends. A first set of the plurality of abrasive features (i) has an average height, H.sub.1avg, (ii) a standard deviation of less than 10% of H.sub.2avg, and (iii) comprises between 5 and 130 abrasive features.

An abrasive article includes a plurality of abrasive features disposed on one or more abrasive elements. Each of the one or more abrasive elements includes a base having a first major surface from which the plurality of abrasive features extends. A first set of the plurality of abrasive features (i) has an average height, H.sub.1avg, (ii) a standard deviation of less than 10% of H.sub.2avg, and (iii) comprises between 5 and 130 abrasive features.

A method of making a coated abrasive article includes at least four steps. In step a), a web is provided comprising a backing having a make layer precursor disposed thereon. The web moves along a web path in a downweb direction, and the web has a crossweb direction that is perpendicular to the downweb direction. The make layer precursor comprises a first curable binder precursor; In step b) an applied magnetic field is provided. In step c), a mixture of magnetizable non-magnetizable particles is passed through the applied magnetic field and onto the make layer precursor such that the magnetizable and non-magnetizable particles are predominantly deposited onto the web in a drop zone according to a predetermined order. At least one of the magnetizable particles or the non-magnetizable particles comprises abrasive particles. In step d), the make layer precursor is at least partially cured to provide a make layer.

A method of making a coated abrasive article includes at least four steps. In step a), a web is provided comprising a backing having a make layer precursor disposed thereon. The web moves along a web path in a downweb direction, and the web has a crossweb direction that is perpendicular to the downweb direction. The make layer precursor comprises a first curable binder precursor; In step b) an applied magnetic field is provided. In step c), a mixture of magnetizable non-magnetizable particles is passed through the applied magnetic field and onto the make layer precursor such that the magnetizable and non-magnetizable particles are predominantly deposited onto the web in a drop zone according to a predetermined order. At least one of the magnetizable particles or the non-magnetizable particles comprises abrasive particles. In step d), the make layer precursor is at least partially cured to provide a make layer.

An abrasive product has a flexible abrasive area for abrading surfaces to be abraded and comprises: a fabric; a plurality of flexible loops protruding from the fabric towards the flexible abrasive area, wherein each loop is formed by a pair of bottom-half arcs, a pair of legs and a head, wherein the pair of legs connects the pair of bottom-half arcs with the head, the bottom-half arcs of the loops are interlaced in rows in the fabric and form rows of interlaced bottom-half arcs, wherein the legs and heads protrude from the fabric, the heads of the loops are interconnected with one another at a distance to the fabric such that the flexible abrasive area is at a distance to the fabric, and the heads of the loops are at least partially provided with abrasive particles and form the flexible abrasive area.