A metal matrix composite tool includes a body having hard composite portion that includes reinforcing particles dispersed in a binder material. At least some of the reinforcing particles comprise a monolithic particle structure including a core having irregular outer surface features integral with the core.

A rolling depth of cut controller (DOCC) includes a first retainer including a body portion having an arcuate inner surface. The body portion extends partially around a central axis between the inner surface and an outer surface from a mating surface to an engagement surface. Further, the body portion extends axially along the central axis. The rolling DOCC also includes a second retainer secured to the first retainer at the mating surface via at least one fastening feature. Additionally, the rolling DOCC includes a rolling element disposed at least partially within a cavity formed between the first retainer and the second retainer. The rolling element is configured to rotate within the cavity about the central axis, and an exposed portion of the rolling element is configured to provide depth-of-cut control for a drill bit.

A rolling depth of cut controller (DOCC) includes a first retainer including a body portion having an arcuate inner surface. The body portion extends partially around a central axis between the inner surface and an outer surface from a mating surface to an engagement surface. Further, the body portion extends axially along the central axis. The rolling DOCC also includes a second retainer secured to the first retainer at the mating surface via at least one fastening feature. Additionally, the rolling DOCC includes a rolling element disposed at least partially within a cavity formed between the first retainer and the second retainer. The rolling element is configured to rotate within the cavity about the central axis, and an exposed portion of the rolling element is configured to provide depth-of-cut control for a drill bit.

An instrumented cutter including a polycrystalline diamond table bonded to a substrate with a sensor, for monitoring the condition of the polycrystalline compact diamond table, embedded in the substrate. Further the instrumented cutter includes a wireless transmitter equipped with a power supply to power to the wireless transmitter.

Polycrystalline diamond bodies having an annular region of diamond grains and a core region of diamond grains and methods of making the same are disclosed. In one embodiment, a polycrystalline diamond body includes an annular region of inter-bonded diamond grains having a first characteristic property and a core region of inter-bonded diamond grains bonded to the annular region and having a second characteristic property that differs from the first characteristic property. The annular region decreases in thickness from a perimeter surface of the polycrystalline diamond body towards a centerline axis.

Polycrystalline diamond bodies having an annular region of diamond grains and a core region of diamond grains and methods of making the same are disclosed. In one embodiment, a polycrystalline diamond body includes an annular region of inter-bonded diamond grains having a first characteristic property and a core region of inter-bonded diamond grains bonded to the annular region and having a second characteristic property that differs from the first characteristic property. The annular region decreases in thickness from a perimeter surface of the polycrystalline diamond body towards a centerline axis.

A method of forming a cutting element comprises forming a first material comprising discrete coated particles within a container. The first material is pressed to form a first green structure comprising interbonded coated particles. A second material comprising additional discrete coated particles is formed over the first green structure within the container. The second material is pressed to form a second green structure comprising additional interbonded coated particles. The first green structure and the second green structure are sintered to form a multi-layered cutting table. Additional methods of forming a cutting element, a cutting element, and an earth-boring tool are also described.

A method of forming a cutting element comprises forming a first material comprising discrete coated particles within a container. The first material is pressed to form a first green structure comprising interbonded coated particles. A second material comprising additional discrete coated particles is formed over the first green structure within the container. The second material is pressed to form a second green structure comprising additional interbonded coated particles. The first green structure and the second green structure are sintered to form a multi-layered cutting table. Additional methods of forming a cutting element, a cutting element, and an earth-boring tool are also described.

The present disclosure relates to an earth-boring drill bit including a shank, an internal region formed from at least a first alloy using additive manufacturing and secured to the shank, and an exterior region formed from at least a second alloy using additive manufacturing and secured to the internal region using additive manufacturing. The first alloy and the second alloy have a different modulus of elasticity, yield strength, resilience, ductility, hardness, fracture toughness, wear resistance, corrosion resistance, or erosion resistance. The disclosure further includes a method of manufacturing such an earth-boring drill by depositing a plurality of layers according to a drill bit specification using additive manufacturing.

The present disclosure relates to an earth-boring drill bit including a shank, an internal region formed from at least a first alloy using additive manufacturing and secured to the shank, and an exterior region formed from at least a second alloy using additive manufacturing and secured to the internal region using additive manufacturing. The first alloy and the second alloy have a different modulus of elasticity, yield strength, resilience, ductility, hardness, fracture toughness, wear resistance, corrosion resistance, or erosion resistance. The disclosure further includes a method of manufacturing such an earth-boring drill by depositing a plurality of layers according to a drill bit specification using additive manufacturing.