An improved method for controlling nucleation sites during superabrasive
particle synthesis can provide high quality industrial superabrasive
particles with high yield and a narrow size distribution. The synthesis
method can include forming a raw material layer, forming a particulate
catalyst layer adjacent the raw material layer, and placing crystalline
seeds in a predetermined pattern at least partially in the catalyst layer
or raw material layer to form a growth precursor. Alternatively, the raw
material and catalyst material can be mixed to form a particulate crystal
growth layer and then placing the crystalline seeds in a predetermined
pattern in the growth layer. Preferably, seeds can be substantially
surrounded by catalyst material. The growth precursor can be maintained
at a temperature and pressure at which the superabrasive crystal is
thermodynamically stable for a time sufficient for a desired degree of
growth. The crystalline seeds can be placed in a predetermined pattern
using a template, a transfer sheet, vacuum chuck or similar techniques.
The superabrasive particles grown using the described methods typically
have a high yield of high quality industrial particles and a narrow
distribution of particle sizes.