A method of forming a rotary cutter includes forming at least one longitudinally-extending flute along a body of a rotary blank, and forming a plurality of pockets along the at least one longitudinally-extending flute. A plurality of polycrystalline diamond (PCD) segments are attached to the body, wherein each PCD segment of the plurality of PCD segments is attached to a respective pocket of the plurality of pockets. A cutting edge is formed along a leading edge of each of the PCD segments.