Importance

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Abstract

An abrasive article is provided having a sheet-like structure having a major surface having deployed in fixed position thereon a plurality of abrasive three-dimensional abrasive composites, each of the composites comprising abrasive particles dispersed in a binder and having a precise shape defined by a distinct and discernible boundary which includes specific dimensions, wherein the precise shapes are not all identical. The invention also relates to a method of manufacturing such an abrasive article, involving, generally, the steps of: (1) introducing a slurry containing a mixture of a binder and a plurality of abrasive grains onto a production tool; (2) introducing a backing to the outer surface of the production tool such that the slurry wets one major surface of the backing to form an intermediate article; (3) at least partially curing or gelling the binder before the intermediate article departs from the outer surface of the production tool to form an abrasive article; and (4) removing the abrasive article from the production tool, wherein the shapes of the abrasive composites formed are not all identical. The invention also relates to a production tool useful to make the abrasive article and method of using such an abrasive article to reduce a surface finish at a high cut-rate, to produce a fine finish without generating grooves.

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First Claim