3D Diamond Bulk Structuring by Laser-Induced Graphitization
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Solution Overview
Problem
Existing diamond shaping processes are inefficient and labor-intensive, requiring multiple manual steps and resulting in significant loss of diamond material due to the need for manual polishing and the inability to create complex shapes.
Innovation Solution
A system utilizing ultrafast and ultra-violet lasers to irradiate diamond bulk, creating graphitization at specific locations, with a movable platform and processor-controlled movement to precision-cut and extract predetermined structures, minimizing material loss and enabling rapid creation of complex three-dimensional shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual polishing and shaping methods are used, then human intervention and control are maintained, but the process becomes labor-intensive and time-consuming with significant material loss
Solution Approach 1:
The patent replaces manual mechanical polishing and shaping operations with an automated laser-based system. The laser irradiation system automatically creates graphitization at predetermined locations within the diamond bulk, eliminating the need for manual intervention between shaping steps and dramatically reducing both processing time and preparation intervals.
Solution Approach 2:
The system performs preliminary graphitization at precise locations before extraction. By creating the graphitization pattern in advance according to the predetermined structure design, the system enables subsequent easy removal of graphitized portions and clean extraction of the desired diamond structure, streamlining the entire manufacturing process.
2Manufacturing precision
If manual polishing is used to achieve desired shapes, then flexibility in design is maintained, but material loss increases due to the subtractive nature of manual polishing
Solution Approach 1:
The laser irradiation system applies energy selectively at specific predetermined locations within the diamond bulk, creating graphitization only where needed for the desired structure. This localized approach preserves surrounding diamond material that would otherwise be removed in manual polishing, significantly reducing overall material loss while achieving the exact shape accuracy required.
Solution Approach 2:
The system changes the physical state of diamond material at targeted locations through laser-induced graphitization, transforming it from diamond crystal structure to graphite. This parameter change enables precise shape definition without the material loss inherent in mechanical subtractive processes, as only graphitized portions are removed.
3Extent of automation
If traditional laser cutting is used, then automated processing is achieved, but the ability to create complex three-dimensional structures is limited
Solution Approach 1:
The system extends laser processing from traditional two-dimensional surface cutting into the third dimension by focusing laser irradiation at predetermined locations within the bulk diamond material. This enables creation of complex three-dimensional structures with internal graphitization patterns, allowing automated fabrication of shapes that were previously impossible to achieve with conventional laser cutting methods.
Solution Approach 2:
The diamond bulk is processed through segmented stages: first graphitization at multiple predetermined locations is created throughout the bulk, then the graphitized portions are removed, and finally the predetermined structure is extracted. This segmentation of the manufacturing process enables complex three-dimensional shaping that combines automated precision with structural complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system allows for the automatic creation of precise diamond structures in a fraction of the time required by traditional methods, reducing material loss and enabling the extraction of polished diamonds for further use, while allowing for the creation of complex shapes previously impossible with manual polishing.
Implementation Method 1
the laser may create graphitization at locations where the focal point of the laser engages the diamond bulk
Implementation Method 2
the laser may emit light having pulses of less than 200 nanosecond seconds
Implementation Method 3
the method may further include removing of the graphite from the diamond bulk using oxidation
Data Source
AI summary
Aspects of the invention may be directed to a method of creating a predetermined structure from a diamond bulk. In some embodiments, the method may include: irradiating the diamond bulk with at least one laser having a focal point at a predetermined location, the laser may create graphitization at locations where the focal point of the laser engages the diamond bulk; at least one of: moving the diamond bulk to be positioned with the focal point of the laser within the diamond bulk, and moving the at least one laser such that diamond bulk be positioned with the focal point of the laser, along at least one axis wherein the movement corresponds to a predefined scheme; removing of the graphite from the diamond bulk; and extracting the predetermined structure from the diamond bulk.