A lithography based method for the manufacture of diamond composite materials in which green bodies are prepared by a layer-by-layer construction with resulting green bodies de-bound and sintered to achieve a dense high hardness material.

A drill bit includes a bit body providing a plurality of blades disposed about a centerline of the bit body, one or more primary cutters mounted at a leading face of each blade, and one or more offset cutters mounted to at least one of the plurality of blades and angularly offset from a laterally adjacent primary cutter and the leading face of the at least one of the plurality of blades.

A drill bit includes a bit body providing a plurality of blades disposed about a centerline of the bit body, one or more primary cutters mounted at a leading face of each blade, and one or more offset cutters mounted to at least one of the plurality of blades and angularly offset from a laterally adjacent primary cutter and the leading face of the at least one of the plurality of blades.

Rotary drill bits may include on or more cutting element assemblies which include a cutter and a mounting system. In one embodiment, the mounting system includes a housing, a first bearing component disposed within the housing, and a second bearing component associated with the cutting element. In certain embodiments, the bearing components may comprise a table of superhard material bonded with a substrate. In one or more embodiments, the bearing components may include bearing surfaces that are arcuate. For example, the bearing surfaces may be substantially spherical (a portion of a sphere). The bearing components may be arranged to act as a radial bearing as well as a thrust bearing for the cutting element, enabling the cutting element to rotate about a longitudinal axis of the cutter, relative to the housing, while also enabling the longitudinal axis of the cutter to be displaced (change angles) relative to the housing.

Rotary drill bits may include on or more cutting element assemblies which include a cutter and a mounting system. In one embodiment, the mounting system includes a housing, a first bearing component disposed within the housing, and a second bearing component associated with the cutting element. In certain embodiments, the bearing components may comprise a table of superhard material bonded with a substrate. In one or more embodiments, the bearing components may include bearing surfaces that are arcuate. For example, the bearing surfaces may be substantially spherical (a portion of a sphere). The bearing components may be arranged to act as a radial bearing as well as a thrust bearing for the cutting element, enabling the cutting element to rotate about a longitudinal axis of the cutter, relative to the housing, while also enabling the longitudinal axis of the cutter to be displaced (change angles) relative to the housing.

A cutter system for a polycrystalline diamond compact (PDC) drill bit includes a body; a static blade attached to the body; a translatable blade attached to the body; and at least one PDC cutting structure attached to the translatable blade. The translatable blade is configured to be translated and maintained in a translated position. The body includes a cavity cooperatively positioned angularly away from the static blade. The translatable blade translates into the cavity. The translatable blade has a substantially retracted rest position and a substantially extended rest position. The cavity includes a restricting device within said cavity, so that said restricting device engages said translatable blade member in the substantially retracted position or the substantially extended position.

A cutter system for a polycrystalline diamond compact (PDC) drill bit includes a body; a static blade attached to the body; a translatable blade attached to the body; and at least one PDC cutting structure attached to the translatable blade. The translatable blade is configured to be translated and maintained in a translated position. The body includes a cavity cooperatively positioned angularly away from the static blade. The translatable blade translates into the cavity. The translatable blade has a substantially retracted rest position and a substantially extended rest position. The cavity includes a restricting device within said cavity, so that said restricting device engages said translatable blade member in the substantially retracted position or the substantially extended position.

Polycrystalline diamond constructions are formed from a mixture of diamond grains including a first volume of fine-sized diamond grains, and a second volume of coarse-sized diamond grains. The fine-sized diamond grains are partially graphitized, and the coarse-sized diamond grains are not graphitized. The mixture of diamond grains is subjected to high pressure/high temperature sintering process conditions in the presence of a sintering aid thereby forming polycrystalline diamond. Contact areas between coarse-sized diamond grains in the polycrystalline diamond construction are substantially free of graphite.

Polycrystalline diamond constructions are formed from a mixture of diamond grains including a first volume of fine-sized diamond grains, and a second volume of coarse-sized diamond grains. The fine-sized diamond grains are partially graphitized, and the coarse-sized diamond grains are not graphitized. The mixture of diamond grains is subjected to high pressure/high temperature sintering process conditions in the presence of a sintering aid thereby forming polycrystalline diamond. Contact areas between coarse-sized diamond grains in the polycrystalline diamond construction are substantially free of graphite.

A new horizontal directional drilling (HDD) bit comprising a bit body is provided with illustrated embodiments including a flat bit design and a cobble bit design. Cutter teeth may be cut (e.g. formed or machined) into the base steel material of the bit body. Additionally, a broken edge profile may be generated to avoid sharp corners for better receipt of hard facing material such as laser clad beads that may be applied in higher wear regions.