normablue writes: http://www.usatoday.com/tech/news/techinnovations/2005-10-06-man-made-diamonds_x.htm
BOSTON
— In the back room of an unmarked brown building in a run-down strip
mall, eight machines, each the size of a bass drum, are making diamonds.
That's
right — making diamonds. Real ones, all but indistinguishable from the
stones formed by a billion or so years' worth of intense pressure,
later to be sold at Tiffany's.
The
company doing this is Apollo Diamond, a tiny outfit started by a former
Bell Labs scientist. Peer inside Apollo's stainless steel-and-glass
machines, and you can see single-crystal diamonds literally growing
amid hot pink gases.
This year,
Apollo expects to grow diamonds as big as 2 carats. By the end of 2005,
it might expand to 10 carats. The diamonds will probably start moving
into the jewelry market as early as next year — at perhaps one-third
the price of a mined diamond.
The
whole concept turns the fundamental idea of a diamond on its head. The
ability to manufacture diamonds could change business, products and
daily life as much as the arrival of the steel age in the 1850s or the
invention of the transistor in the 1940s.
In
technology, the diamond is a dream material. It can make computers run
at speeds that would melt the innards of today's computers.
Manufactured diamonds could help make lasers of extreme power. The
material could allow a cellphone to fit into a watch and iPods to store
10,000 movies, not just 10,000 songs. Diamonds could mean frictionless
medical replacement joints. Or coatings — perhaps for cars — that never
scratch or wear out.
Scientists have
known about the possibilities for years. But they've been held back
because mined diamonds are too expensive and too rare. And they're hard
to form into wafers and shapes that would be most useful in products.
Manufacturing
changes that. It's like the difference between having to wait for
lightning to start a fire vs. knowing how to start it by hand.
"I'm
just so completely awed by this technology," says Sonia Arrisonof tech
analysis group Pacific Research Institute. "Basically, anything that
relies on computing power will accelerate."
Arno
Penzias, a venture capitalist and Nobel Prize winner for physics, says,
"This diamond-fabrication story marks a high-profile milestone on an
amazing scientific journey."
"We
can't begin to see all the things that can happen because single
diamond crystals can be made," says Apollo co-founder Robert Linares,
elegant and slim in a golf shirt, slacks and loafers as he sits at the
two plastic folding tables that make up Apollo's low-budget conference
room. "We are only at the beginning."
Linares
has worked on the technology for 15 years, much of that time in his
garage. From the start, he did this because of the promise of diamonds
in technology. Linares wasn't trying to make gems. In fact, he didn't
think he could.
Then he had a happy accident. Well, actually, time will tell whether the accident was a happy one.
Two different paths to diamonds
In
1955, General Electric figured out how to use room-size machines to put
carbon under extremely high pressure and make diamond dust and chips.
The diamond material wasn't pure or big enough for gems or digital
technology. But it had industrial uses, such as diamond-tipped saws.
Such saws made it possible, for instance, to cut granite into
countertops.
In the ensuing decades,
companies and inventors tried to make bigger, better diamonds. But they
didn't get far. By the 1990s, researchers were focused on two different
paths to diamonds.
One was brute
force. Some Russians became pretty good at it, and their machines were
eventually brought to Florida by Gemesis. That company now crushes
carbon under 58,000 atmospheres of pressure at 2,300 degrees
Fahrenheit, until the stuff crystallizes into yellowish diamonds. The
stones are attractive for jewelry but not pure enough for digital
technology. Gemesis sells its gems through retailers at around $5,000
per carat. A mined yellow diamond can cost four times more.
The
other process is called chemical vapor deposition, or CVD. It's more
subtle. It uses a combination of carbon gases, temperature and pressure
that, Linares says, re-creates conditions present at the beginning of
the universe. Atoms from the vapor land on a tiny diamond chip placed
in the chamber. Then the vapor particles take on the structure of that
diamond — growing the diamond, atom by atom, into a much bigger
diamond.
CVD
can make diamonds that are clear and utterly pure. It's also a way to
make diamond wafers, much like silicon wafers for computer chips. The
CVD process can be tweaked by putting in enough boron to allow the
diamond to conduct a current. That turns the diamond into a
semiconductor.
A handful of companies
and scientists, including Sumitomo in Japan and the global diamond
powerhouse De Beers, have chased CVD. But by most accounts, Linares is
out front.
After receiving his
doctorate in materials science from Rutgers University, Linares joined
Bell Labs and worked on crystals that would be crucial in
telecommunications. In the 1980s, he started Spectrum Technology to
make single-crystal Gallium Arsenide chips, one of the key components
in cellphones. Spectrum became the material's biggest U.S. supplier,
and Linares eventually sold the company to NERCO Advanced Materials.
He
then dropped out of business, putting his time and money into his pet
project: making CVD diamonds for cutting tools and electronics.
"Gemstones were the furthest thing from my mind," Linares says.
Breakthrough in a garage workshop
Linares
built machines in his garage, superheating carbon in suburban Boston
while his neighbors went about their lives. He got the CVD process to
work, at first making tiny diamond chips. He formed Apollo and started
down the path to industrial diamonds. Then Linares inadvertently left a
diamond piece in a beaker of acid over a weekend. The acid cleaned up
excess carbon — essentially coal — that had stayed on the diamond.
"When
I came in Monday, I couldn't see the (stone) in the beaker," Linares
says. The diamond was colorless and pure. "That's when I realized we
could do gemstones."
For
Apollo, there are lots of good things about making gems. Diamond
jewelry will be a $60 billion global market this year, and it's growing
fast. If Apollo can snag just 1%, the company would become a $600
million rocket.
Also, gems could
become a source of revenue quickly. While the military and companies
are working on tech inventions that use diamonds, a real market for
diamond technology might be a decade away. By selling gems, Apollo can
make money now to fund the research for forthcoming diamond tech
products.
That solution, though,
brings two huge problems. One is that Apollo doesn't know the gem
business. Its employees are technologists. Aside from Linares, Apollo
is run by his son, Bryant, an MBA who started and sold an information
services company. Vice President Patrick Doering had been lead
scientist at Spectrum.
"We are not
gemstone guys," Bryant Linares admits. They don't know consumer
marketing or retailing. Bryant Linares notes that Apollo plans to split
into a tech business run by the Linareses and a gem business run by a
gem veteran they have yet to hire. For now, though, the gem business is
a distraction with a steep learning curve.
Apollo's
other problem is De Beers, which doesn't like what Apollo is doing one
bit. De Beers launched a public relations campaign and an education
program for jewelers, all aimed at portraying mined diamonds as real
and eternal — and CVD or Gemesis diamonds as fake and tacky.
Both
Apollo and Gemesis want to market their gems as "cultured diamonds,"
taking a cue from cultured pearls. De Beers is fighting that label.
"It's misleading and unacceptable," says De Beers executive Simon
Lawson. "It makes people think (manufacturing diamonds) is an organic
process, and it's not."
Even highly
trained diamond experts find it almost impossible to tell a CVD diamond
from a mined one. De Beers is determined to help by making machines
that can detect the slightest difference in the way the two materials
refract light.
As part of that
effort, De Beers stepped up its own CVD research "focused on producing
state-of-the-art synthetic diamonds for testing on our equipment,"
Lawson says. Referring to CVD diamonds, he adds, "We don't see
gemological applications fitting into it."
So by getting into gems, little Apollo made a powerful, determined enemy.
A long list of possibilities
The tech side is an entirely different story. Just about every entity in technology can get excited about diamonds.
The
military's DARPA research arm has been pumping money into CVD projects.
Companies such as Lucent are on the trail of holographic optical
storage, which will use lasers to store data in 3D patterns, cramming
huge amounts of information in tiny spaces. CVD diamonds would vault
holographic storage ahead, helping bring about the 10,000-movie iPod.
Tech
company Textron is a big fan of Apollo. Textron has been working on
super lasers that might become weapons or be used like a camera flash
for spy satellites, so they could take photos from space at night.
"Thermal
management is a major challenge to increasing a laser's power,"
explains Textron scientist Yulin Wang. The diamond has the highest
thermal conductivity of any material, which allows it to quickly move
heat away from the laser's insides. Textron needs large, pure diamond
pieces for its lasers and finally found them at Apollo.
CVD
diamonds can help solve one of the computer industry's biggest
challenges. Companies such as Intel advance computer chip technology by
squeezing microscopic wires closer together while making the chips run
ever faster. But that's making the chips increasingly hotter. At some
point this decade, the chips could run so hot they'd melt. But not if
the chips were based on diamond wafers instead of silicon.
"Using
diamonds as semiconductors will continue Moore's Law," says Pacific
Research's Arrison, referring to an observation about the continual
increase in speed and power since chips were invented.
The
list of possibilities for man-made diamonds goes on. "By most measures,
diamond is the biggest and best," says a research paper written about
CVD by Paul May at the U.K.'s University of Bristol. It's the hardest
material, it won't expand in heat, won't wear, is chemically inert and
optically transparent, May says.
"Once (manufactured) diamond is available, developers will find all kinds of other things to do with it," Robert Linares says.
Manufactured
diamonds will be like other inventions that were so profound because
they made new things possible. Steel allowed engineers to dream of
skyscrapers and suspension bridges. Transistors led to computers and
pacemakers and so much else. So this may be the beginning of the
diamond age of technology.
Says Linares: "The genie is out of the bottle, and it can never be put back in."