Positive relief forming of polycrystalline diamond structures and resulting cutting tools

1. A method of making a polycrystalline diamond (“PCD”) structure, the method comprising:

providing a substrate having a surface;

positioning at least one diamond material flute volume including at least one diamond material tube including diamond particles, the at least one diamond material tube in contact with a portion of the surface of the substrate; and

subjecting the substrate and the at least one diamond material flute volume to a high-pressure/high-temperature (“HPHT”) process effective to sinter the diamond particles to form a PCD flute volume and bond the PCD flute volume.

2. The method of claim 1 , wherein the at least one diamond material tube includes a cobalt-containing tube.

3. The method of claim 1 , further comprising attaching at least one portion of the PCD flute volume to the substrate using at least one of induction heating, laser tacking, adhesive, or a binder material.

4. The method of claim 1 , wherein the at least one diamond material flute volume includes a plurality of shear compacted diamond particles.

5. The method of claim 1 , wherein positioning the at least one diamond material flute volume includes positioning at least one preformed diamond volume generally helically around at least a portion of the substrate.

6. The method of claim 1 , further comprising:

removing mold material from around the PCD flute volume and the substrate;

processing the PCD flute volume to a final dimension using at least one of milling, grinding, lapping, electro-discharge machining, or lasing; and

at least partially leaching the PCD flute volume to a selected depth therein.