Abstract

Using the DC arc deposition technique, we are scaling the diamond deposition process up to high excitation power in order to reduce the manufacturing cost and increase the production rate of polycrystalline diamond. We have operated the process with plasma torches up to 100 kW. A 1/2 MW facility is under construction.

The approach has been guided by a production cost model that takes into account labor, materials, utilities, overhead, depreciation, and cost of capital to project manufacturing costs. The model has identified and quantified the important parameters that are required to achieve low manufacturing cost. Specifically, it has demonstrated the importance of operating at high power and of recycling non-consumed feed gases.

© 1995 Optical Society of America