March 21, 2014

Diamond Production Innovation - Mass Production

Diamond Production Innovation - Mass Production

By: Michael McMahon – COO – Scio Diamond Technology Corporation

Is the real “disruptive technology innovation” of cultured diamond for the industrial world, “mass production?” Throughout the last six or seven decades man has produced, in one shape or another, “man-made” diamond. It has many names including cultured diamond, lab-grown diamond, man-made diamond, HPHT, CVD, etc. Some have even attempted to place CZ into this category.

As is the case in most industries, only a few survive. Those companies that are surviving today, few that they are, can truly make “diamond.” Not natural diamond, not pretend diamond, but “REAL DIAMOND.”

While some producers have the ability to make beautiful gemstones in varying colors and grades, the industrial need for diamond is almost beyond belief. Through research and development efforts around the world, hundreds, if not thousands, of brilliant scientists and PhD’s have developed a multitude of uses for diamond in the industrial and commercial arenas. More are being developed every day.

There are literally so many potential applications for industrial diamond that the demand cannot be met. Moreover, the quantities now being supplied are not being produced economically, limiting the real quantities demanded. The failure to produce economically feasible diamond for industrial use is robbing the world of the material’s dynamic benefit.

Diamond Growth

Scio Diamond’s mission is to end the drought. Scio Diamond has just begun production of CVD Single Crystal Diamond in Greenville, SC. Its patented methodologies and processes, combined now with good manufacturing discipline, support Scio’s drive to mass production. Scio has started its mass production advancement process that will culminate in the production of over 150,000 gross carats of diamond annually from less than 15 reactors. The core of this mass production drive will be the application of Scio’s multiple patented growing technologies.

Scio’s proven process for seed replication and harvesting and Mosaic seed creation allows it to advance rapidly from its production startup of multiple diamond seeds measuring up to twenty four (5mm x 5mm) to multiple Mosaic seeds measuring at a minimum of 25mm x 25mm, in the same reactor. Note, for comparison purposes, the grow time for all runs in this article is approximately 7 days. The expected up time of the reactors is 90% or greater.

The photo below shows Scio’s S3532 technology. This picture shows 2,4 5mm x 5mm seeds in the reactor growing simultaneously.

scio-diamond

The S3532 technology is used initially for Scio’s self-sustaining seed production, as well as numerous industrial uses, specifically in the cutter blade market sector. Upon completion of a S3532 growth run, each seed will yield a rough diamond of approximately 2 gross carats or up to 64 gross carats per run.

Following the successful completion of Scio’s growth run at S3532 technology, Scio will implement its 2nd phase of proven S3724 technology. The S3724 technology is generally the same as S3532 but with differences in the seed size and the number of seeds on the growing platform. The minimum size seed in these runs is 7mm x 7mm. This technology will yield up to 92 rough gross carats per run or a 48% increase over the S3532 technology.

These two technologies are based on Scio’s 3” growing platform. It should be noted that each of these technologies could be increased dramatically by changing to the 4” growing platform, thereby increasing growing capability by another 78%. The gross carat yield expectation would expand in line with that capability.

In parallel with the production runs using S3532 and S3724 technologies, Scio Diamond will be growing its larger seeds. This is accomplished by using a patented Mosaic Process.

The Scio Grown Diamond Mosaic Separation is the patented process used by Scio to replicate and then fuse multiple seed diamonds. This process allows for separation at an atomic level, making possible the production of large volume single crystals.

Depending on product demand, Scio will be progressively creating seeds in multiple bar and plate formations to adapt to customers’ specific needs. This configuration will use the proven S31M and S48M technologies. Seed sizes will be created to grow product ranging from 5mm x 10mm x 1/2mm thick, to 28mm x 28mm x 5mm thick.

The photo below shows Scio’s S31M technology. This picture shows a 25mm x 25mm seed, with approximately 750 microns of growth after a single day’s growth.

scio-diamond

At full growth this diamond plate will measure 25mm x 25mm x 4-5mm thick, yielding 39-49 gross carats of diamond from each plate. The yield of 39-49 diamond gross carats is dependent on finished thickness and actual seed width and length. In addition, Scio will make customized bars of diamond focusing on specific clients, or a cluster of clients desiring similar requirements. For instance, if a 3mm x 2mm x 1mm finished diamond part is needed, Scio will optimize the growth dimensions to enable efficient fabrication of the final product.

The photo below shows Scio’s S35M technology. This picture shows 5, 25mm x 25mm seeds, with approximately 750 microns of growth.

scio-diamond

At full growth on non-specialized runs, the S35M technology utilizing five 25mm x 25mm Scio generated seeds will produce between 195 and 245 gross carats per run.

Scio’s most recent proven technology is its S48M generation (not pictured). The S48M, which begins with eight 25mm x 25mm seeds and at full growth is 4-5mm thick, yielding between 312 and 392 diamond gross carats per run. Each of the aforementioned technologies will average approximately 45 runs per year.

Fabrication

Given this mass production of cultured diamond for industrial uses, the need for increased capability for fabrication and polishing becomes the next hurdle. Diamond growth is not a labor-intensive business. While multiple growers, once started and in cycle, can be run by one operator, great attention to detail is needed in operating lasers and polishing operations and the ratio of labor to machine is higher.

Example: The Scio S35M technology at 1.2MM growth thickness produces approximately 55 gross carats per 3 day run. Now your client wants you to produce 3mm x 2mm x 1mm cutter blades and they need to be polished on top and bottom. How many blades can you get from (5) five, 25mm x 25mm x 1.2mm seamless diamond plates? The math tells you with a 20% kerf loss you would have approximately 400. If your client wants 1,000 of these per month, how many lasers and operators will you need to fabricate and polish for this single customer?

Summary

What does all this mean to the industrial diamond market? It is GOOD NEWS! As more and more diamond is available and production is economically scalable, the hundreds of industrial applications have a much greater chance of coming to fruition for the masses and allowing the world to experience the impact of life-altering technology that diamond can bring. Through innovation and the application of proven science and technologies and matching that with GMP processes, large quantities of diamond material can be now be made economically per client requirements.

 

 

OTC Investor Article

Scio Diamond’s (SCIO) Disruptive Technology a True Gem for Investors
By Andrew Klips · Monday, March 5th, 2012

A diamond may generally be thought of for its value as a gemstone, but it is also the world’s most versatile engineering material because of its unparalleled properties and number of industrial and commercial applications. After all, it is the hardest material known to man and has a thermal conductivity (tremendous heat can pass through it without damaging the diamond) that is unmatched by any other known solid. Sure, the gem component of a diamond is sexy, but the stone is so much more to the industrial world. 150 million carats of diamonds are mined each year with De Beers and its now majority shareholder Anglo American plc (LSE: AAL) holding the reigns as industry stalwart for more than 100 years. But, the times are changing as miners like Rio Tinto (NYSE: RIO) and Petra Diamonds, Inc. (LSE:PDL) are steadily cutting into the market share of the De Beers cartel. On a broader perspective, all of the legacy miners are facing threats to lose market share as cultured diamond manufacturing by companies like Scio Diamond Technology Corporation (OTCBB: SCIO) has moved to the forefront of the industry for all that it has to offer.

The Dark Side of Diamond Mining
Because of the high value of a diamond, greed has fueled harvesting for centuries. De Beers, the beast of the market, has been frequently accused of antitrust violations and just eight years ago gave up on a ten-year fight by pleading guilty to charges of colluding with General Electric (NYSE: GE) to fix the price of industrial diamonds.

Diamond smuggling and illegal mining practices swirl through the media surrounding the precious stone. The “Blood Diamonds” of the civil war in the 1990’s and early 2000’s in South Africa garnered worldwide infamy as smuggled diamonds funded military operations of rebels and exposed the prevalence of diamond trafficking for military might. Diamond mining in Zimbabwe is in the news as mandated transparency of diamond mining is being ignored, leading to an investigation of miners hoarding profits for themselves by Finance Minister Tendai Biti.

The list for the dark side of the bright rock goes on and on, including illegal child labor, serious health and safety hazards and environmental damage as diamond mining turns the earth’s crust into Swiss cheese. Some of the largest manmade holes in history were done for the sake of diamonds, like the Mir Mine and Udachnaya Diamond Mine in Russia; “The Big Hole” and nearby Jagersfontein Mine in South Africa; and the Diavik Diamond and Ekati Diamond Mines in Canada. Unlike metal mining, where veins are identified and followed, diamond mining is akin to “finding a needle in a haystack” where massive amounts of earth are devoured in search of a single carat.

An American Solution
In simplistic terms, making a diamond is easy; put pure carbon under enough heat and pressure and it will crystalize into a diamond. That’s the way the Earth has been making them for millions of years. The technology to make real diamonds in a lab has been evolving for decades and is ready to go mainstream to provide an expandable product and solution to the ignominious ways of the diamond industry.

Yes, cultured diamonds are real diamonds. Whereas Moissanite is brilliant and the difference between it and a real diamond cannot be detected by the human eye, it is still basically a piece of glass. Cultured, lab-grown diamonds are made through earth’s natural processes of heating and compressing carbon far more efficiently to expedite and control the process to perfection.

Recognizing the possibilities of the disruptive technology, Stuart Brown, Finance Director at De Beers, told Bloomberg in 2007, “We don’t see synthetic diamonds as a threat, but you cannot ignore it completely.” Two years later the company acknowledged that they could not get diamonds out of the ground fast enough to meet demand.

Competition within the cultured diamond industry is somewhat scarce with Scio Diamonds perched atop the leaders. The company’s technology has been twenty years in the making under the guidance of Dr. Robert Linares of Apollo Diamond in Boston, with Scio buying certain assets of Apollo in April 2011 to commercialize the technology. The Intellectual Property of Scio’s Chemical Vapor Deposition (CVD) technology is protected through 17 issued and 40 pending patents in the U.S. and abroad.

Scio uses reactors and no artificial means or simulants to culture its diamonds in a process that has been proven to control outcomes to manufacture real diamonds of different shapes, sizes and colors to fit the required end product, whether it is a wafer for a semiconductor or a polished gem. Through this revolutionary technology inclusions are controlled, producing a higher quality diamond than most found in nature while still maintaining the identical features of mined diamonds in hardness, thermal conductivity and electron mobility.

How real are they? The Gemological Institute of America (GIA), the world’s foremost authority in gemology, provides a certificate with each diamond produced by Scio, just as they do with mined diamonds. The Institute of Gemology (IGI) and the European Gemological Laboratory (EGL) also rate Scio’s stones.

The diamond industry is once again flourishing as a result of mined diamonds becoming harder to find and demand outpacing supply in the $13 billion dollar industry. There is, of course, the gem factor, but approximately 80 percent of diamond demand is for industrial uses with new technologies poised to increase that figure. For example, laptop computers and mobile phones are plagued with heat dissipation issues that can be resolved by using diamonds in heat sinks and other components to transfer the heat more quickly. Today’s microprocessors have reached terminal velocity as they can’t spin any faster and run any hotter without failing. Diamonds are the answer to these and many more of today’s technology dilemmas.

That’s just a glimpse at possibilities. Other, immediate uses include the de-ionization of water, high power lasers, ultraviolet LEDs and countless defense and energy applications. Advancing these technologies with mined diamonds is simply not economically feasible, but it is through cultured diamonds. Scio has even developed a scalpel with a diamond cutting edge that is unparalleled by any modern scalpel today in form and function.

Scio is knocking down milestones at a frantic pace since acquiring Apollo. New executives and managers have been hired to build upon the $4.5 million in revenue that Apollo had in 2010. The company struck deals to move their lab from Boston to Greenville, South Carolina; a succinct move that garnered Scio huge savings through 85% less power costs. While the production lab moved to SC, the R&D side of Scio moved into a new facility in Hudson, Massachusetts and will be conducting additional research on even larger reactors than the 3 and 6-inch ones that it currently owns.

Distributor deals have been consummated and Scio is working on finalizing a manufacturer agreement with a leading jewelry chain for a line of environmentally friendly diamonds. Additionally, the company expects to make an immediate and high volume splash in medical surgical devices, high thermal conductivity applications (essential to the development of efficient green energy technologies) and water treatment. After building a base in these verticals Scio plans to broaden their scope to capitalize on the almost endless industrial uses for diamond.

The company is debt-free with cash on hand as it nears full-on commercialization and expands revenue from Apollo’s legacy agreements. Scio’s existing reactors are being shipped to the new SC facility and slated for arrival on March 9. “Meanwhile, we continue to build demand for our cultured diamonds as we reach out to distribution and sales prospects, and work to meet their technical specifications,” said Scio CEO Joe Lancia in a recent corporate update.

Much like cultured pearls have moved to complete domination of the industry compared to natural pearls (natural pearls account for less than 1/1000th of a percent of pearl sales today), cultured diamonds possess the same threats to mined diamonds. At worst, cultured diamonds are equal to its natural counterpart, while bringing too many superior qualities to the industry to go overlooked as they are customizable to the end user’s desires at a fraction of the cost. Factor in all of the environmental impacts that can be eliminated and cultured diamonds could be the wave of the future.

For Oppenheimer, diamonds weren’t forever as it bailed from its 40 percent stake in De Beers last year after 80 years of ownership, perhaps signaling where it thinks the mined diamond industry is going. Juxtaposing natural and cultured diamonds reveals an exponential upside for a company like Scio Diamond Technology Corporation in the near term. The diamond industry isn’t going anywhere – in fact it’s going to expand – but where the world gets them from will be the major change.

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