Nozzle, nozzle assembly, and related method

Abstract

Embodiments relate to nozzles for three-dimensional printing and related assemblies and methods. An exemplary method includes forming an aperture in a piece of material on a first side of the piece of material to define an at least partially tapered inner conduit extending at least partially through the piece of material; and forming a through hole in the material piece on a second side of the material piece to define an outlet orifice of the nozzle, the outlet orifice being connected with the at least partially tapered inner conduit to define a fluid path through the nozzle.

Description

Background Art

[0001] Three-dimensional (“3D”) printing is a method that includes dispensing a first layer of material onto a platform through a nozzle. Additional layers of material can be dispensed onto the first and subsequent layers through the nozzle until an object is formed. However, conventional nozzles and conventional nozzle assemblies that include nozzles have some problems, such as unsatisfactory leakage of dispensed material and excessive wear on the nozzle.

[0002] Accordingly, there is a need for new and improved nozzles and nozzle assemblies that include such nozzles. Summary of the Invention

[0003] Embodiments relate to nozzles for three-dimensional printing and related nozzle assemblies, as well as methods of forming and using the nozzles. In an embodiment, a nozzle for three-dimensional printing is disclosed. The nozzle can include at least one top surface, at least one bottom surface opposite the at least one top surface, at least one side surface, and at least one channel surface extending from the at least one top surface to the at least one bottom surface. The at least one channel surface defines a channel. In some embodiments, at least a portion of the at least one channel surface adjacent to the at least one top surface is non-vertical. At least a portion of the at least one channel surface includes at least one superhard material.

[0004] In an embodiment, a nozzle assembly for three-dimensional printing is disclosed. The nozzle assembly includes a base and a nozzle. The base includes an attachment portion configured to attach to a printing device, and the nozzle is attached to the base. The nozzle can include at least one top surface, at least one bottom surface opposite the at least one top surface, at least one side surface, and at least one channel surface extending from the at least one top surface to the at least one bottom surface. The at least one channel surface defines a channel. In some embodiments, at least a portion of the at least one channel surface adjacent to the at least one top surface is non-vertical. At least a portion of the at least one channel surface includes at least one superhard material.

[0005] Some embodiments can include methods of forming and / or using the nozzles and nozzle assemblies.

[0006] For example, a method of forming a nozzle can include: defining at least one channel surface that extends through the nozzle; causing at least a portion of the at least one channel surface to extend in a direction transverse to the central axis of the nozzle; and forming at least a portion of the at least one channel surface using at least one superhard material.

[0007] In some embodiments, a method of using a nozzle during a three-dimensional printing process can include flowing a fluid (e.g., a printing material) through a passage of the nozzle, the passage being defined by a passage surface that includes at least one superhard material and guides the fluid flow through the passage, wherein at least a portion of the passage surface is in a direction transverse to a central axis of the nozzle.

[0008] In some aspects, the techniques described herein relate to a method of forming a nozzle for use during a three-dimensional printing process, the method including: securing a workpiece in a machining fixture; forming a hole in the workpiece on a first side of the workpiece to define an at least partially tapered inner passage that at least partially extends through the workpiece; forming a through-hole in the workpiece on a second side of the workpiece to define an exit orifice of the nozzle, the exit orifice being connected to the at least partially tapered inner passage to define a fluid path through the nozzle; defining the exit orifice to have a height extending in a direction of the fluid path of the nozzle and a width extending in a direction transverse to the height of the exit orifice, the ratio of the height to the width being substantially 1.2 or less; and forming an exterior of the nozzle to remove the nozzle from the remainder of the workpiece.

[0009] In some aspects, the techniques described herein relate to a method of forming a nozzle for use during a three-dimensional printing process, the method including: forming a hole in a workpiece on a first side of the workpiece to define an at least partially tapered inner passage that at least partially extends through the workpiece; reorienting the workpiece to expose a second side opposite the first side; forming a through-hole in the workpiece on the second side of the workpiece to define an exit orifice of the nozzle, the exit orifice being connected to the at least partially tapered inner passage to define a fluid path through the nozzle; and forming an exterior of the nozzle to remove the nozzle from the remainder of the workpiece.

[0010] In some aspects, the techniques described herein relate to a nozzle for three-dimensional printing, the nozzle comprising: at least one proximal surface that defines an inlet of the nozzle; at least one distal surface that is opposite the at least one proximal surface, the at least one distal surface defining an outlet of the nozzle; at least one outer surface that extends from the at least one proximal surface to the at least one distal surface; and at least one duct surface that extends from the at least one proximal surface to the at least one distal surface, the at least one duct surface defining a fluid flow duct through the nozzle; wherein a junction between the at least one duct surface and the at least one distal surface defines an outlet orifice of the nozzle; and wherein the outlet orifice presents a height extending in a direction along the fluid flow duct and a width extending in a direction transverse to the height of the outlet orifice, and the ratio of the height to the width is substantially 1.2 or less.

[0011] The features of any of the disclosed embodiments can be used in combination with each other without limitation. Additionally, other features and advantages of the present disclosure will become apparent to those of ordinary skill in the art by considering the following detailed description and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The drawings illustrate various embodiments of the present disclosure, wherein like reference numerals refer to the same or similar elements or features in different views or embodiments shown in the drawings.

[0013] Figure 1A is an isometric view of a nozzle according to an embodiment.

[0014] Figure 1B is a cross-sectional schematic view of a nozzle according to an embodiment taken along Figure 1A plane 1B-1B shown in

[0015] Figure 1C is an enlarged view of a portion of a nozzle according to an embodiment located within Figure 1B circle 1C shown in

[0016] Figure 1D is an enlarged view of a portion of a nozzle according to an embodiment different from the embodiment shown in Figure 1C located within Figure 1B circle 1C shown in

[0017] Figure 2 is a cross-sectional schematic view of a nozzle according to an embodiment.

[0018] Figure 3 and Figure 4Cross-sectional schematic views of different nozzles including curved pipe surfaces according to different embodiments.

[0019] Figure 5 and Figure 6 Top view of nozzles according to different embodiments, the nozzles all having orifices presenting non-circular cross-sectional shapes.

[0020] Figure 7 and Figure 8 Cross-sectional schematic views of different nozzles according to different embodiments, the nozzles all including chamfered portions extending from their top surfaces to their side surfaces or pipe surfaces.

[0021] Figure 9A Cross-sectional schematic view of a nozzle according to an embodiment, the nozzle being configured to increase the surface area of the printed material formed by the nozzle.

[0022] Figure 9B Enlarged cross-sectional schematic view of a part of a nozzle according to an embodiment, the part including a recess intercepted from circle 9B shown in Figure 9A a recess intercepted from circle 9B shown in

[0023] Figure 9C and Figure 9D Enlarged cross-sectional schematic views of parts of nozzles including recesses according to different embodiments.

[0024] Figure 10 Cross-sectional schematic view of a nozzle according to an embodiment, the nozzle being configured to increase the surface area of the printed material formed by the nozzle.

[0025] Figure 11 Cross-sectional schematic view of a nozzle assembly according to an embodiment, the nozzle assembly including a nozzle attached to a base.

[0026] Figure 12 Cross-sectional schematic view of a nozzle assembly according to an embodiment, the nozzle assembly including a nozzle attached to a base, wherein the maximum lateral dimension is equal to or greater than the maximum lateral dimension of the base.

[0027] Figure 13 Cross-sectional schematic view of a nozzle assembly according to an embodiment, the nozzle assembly including a nozzle but not including a base.

[0028] Figure 14 Schematic view of an embodiment of a method for manufacturing a nozzle from polycrystalline diamond according to an embodiment.

[0029] Figure 15 and Figure 16 Illustrate the internal part of a nozzle defined in a material block according to an embodiment of the present disclosure.

[0030] Figures 17 to 19 Shows an example of a nozzle formed by a process according to an embodiment of the present disclosure. Detailed Description

[0031] The present disclosure relates to nozzles and related nozzle assemblies for three-dimensional printing and methods of forming and using the nozzles. Exemplary nozzles include at least one top surface, at least one bottom surface, and at least one side surface that extends from or near the top surface to or near the bottom surface. The nozzle also includes at least one channel surface that defines a channel. The channel surface extends from or near the top surface to or near the bottom surface. In an embodiment, at least a portion of the channel surface closest to the top surface is non-vertical (e.g., forms a non-cylindrical or non-rectangular shape and extends along an axis transverse to the central axis of the nozzle). In such an embodiment, the channel surface is non-vertical when it is not parallel to (e.g., transverse to) the central axis of the nozzle that extends from the top surface to the bottom surface.

[0032] The features of the nozzles disclosed herein can be configured to, for example, reduce the force required to push printing material through the channel, facilitate removal of a first printing material to prevent contamination of a different second printing material that may subsequently flow through the channel, prevent clogging of the channel, improve heating of the printing material flowing through the nozzle, improve the resolution of the printed material, and / or improve the adhesion of different layers of the printed material. These features can be useful when any printing material flows through the channel, but are particularly useful when abrasive printing material flows through the nozzle. Abrasive printing materials can include printing materials that exhibit a hardness comparable to or greater than the hardness of brass, steel, or other materials commonly used to form nozzles. Examples of abrasive printing materials include polymers, ceramics, metals, composite materials, or combinations thereof in which one or more types of particles (e.g., ceramic particles, metal particles, carbon fibers, etc.) are disposed. It should be noted that, as used herein, "printing material" refers to the material that flows through the channel (e.g., a fluid or other flowable material), and "printed material" refers to the material that has been dispensed through the nozzle.

[0033] The features of the nozzle disclosed herein can form the following features: these features are more likely to wear when the abrasive printing material flows through the pipe, thereby reducing the benefits of the features disclosed herein. Thus, in some embodiments, the nozzle disclosed herein can at least partially include at least one of the following (or can be at least partially formed of at least one of the following): polycrystalline diamond (“PCD”), polycrystalline cubic boron nitride (“PcBN”), another superhard material having a hardness equal to or greater than that of tungsten carbide, and / or any combination of the foregoing. For example, the nozzle can be formed such that: the features of the nozzle disclosed herein can be defined and / or formed by PCD, PcBN, or another superhard material. Additionally, it should be noted that forming at least a portion of the nozzle disclosed herein from at least one of PCD or PcBN can improve the thermal conductivity of the nozzle, thereby improving the heating of the printing material as compared to when the nozzle is formed of another superhard material.

[0034] As used herein, unless the context clearly indicates otherwise, relational terms such as “first,” “second,” “top,” “bottom,” etc. are generally used for clarity and convenience in understanding the present disclosure and the drawings, and do not imply or depend on any particular preference, orientation, or order.

[0035] As used herein, the term “and / or” means and includes any combination and all combinations of one or more of the listed related items.

[0036] As used herein, the terms “vertical,” “upper,” “lower,” and “lateral” refer to the orientation as shown in the drawings.

[0037] Figure 1A is an isometric view of nozzle 100 according to an embodiment. Figure 1B is according to an embodiment of nozzle 100 along Figure 1AA schematic cross-sectional view taken along the plane 1B-1B shown in the figure. The nozzle 100 includes at least one top surface 102, at least one bottom surface 104 opposite to the top surface 102, at least one side surface 106, and optionally one or more chamfered portions (e.g., chamfered portion 108). In the illustrated embodiment, the side surface 106 extends from the top surface 102 to a position near the bottom surface 104 (e.g., extends to the chamfered portion 108 that extends between the bottom surface 104 and the side surface 106). However, it should be noted that the side surface 106 can be at least one of the following two types of extensions: when the nozzle 100 includes an outer chamfered portion that extends between the top surface 102 and the side surface 106, the side surface 106 can extend from a position near the top surface 102, or when the chamfered portion 108 is omitted, the side surface 106 can extend to the bottom surface 104. The nozzle 100 further includes at least one channel surface 110 that defines a channel 112. At least a portion of the channel surface 110 can include at least one superhard material that exhibits a hardness equal to or greater than the hardness of tungsten carbide. This configuration can limit the wear of the channel surface 110. In an embodiment, as shown, the channel surface 110 extends from the top surface 102 to the bottom surface 104. However, the nozzle 100 can include one or more chamfered portions that extend from at least one of the top surface 102 or the bottom surface 104 to the channel surface 110. The top surface 102 and / or the channel surface 110 define an orifice 114 through which printing material is dispensed from the nozzle 100, and the bottom surface 104 and / or the channel surface 110 define an opening 116 through which the channel 112 can receive the printing material.

[0038] As described above, the top surface 102 of the nozzle defines an orifice 114. The orifice 114 may exhibit a maximum lateral dimension (e.g., diameter) that is about 0.25 mm, about 0.4 mm, about 0.6 mm, about 0.8 mm, about 1.0 mm, greater than or about 0.1 mm, greater than or about 0.2 mm, greater than or about 0.4 mm, greater than or about 0.6 mm, greater than or about 0.8 mm, greater than or about 1 mm, greater than or about 1.5 mm, greater than or about 2 mm, less than or about 3 mm, less than or about 2 mm, less than or about 1 mm, less than or about 0.75 mm, less than or about 0.5 mm, or within the range of about 0.1 mm to about 0.3 mm, about 0.2 mm to about 0.4, about 0.3 mm to about 0.5 mm, about 0.4 mm to about 0.6 mm, about 0.5 mm to about 0.7 mm, about 0.6 mm to about 0.8 mm, about 0.7 mm to about 0.9 mm, about 0.8 mm to about 1 mm, about 0.9 mm to about 1.5 mm, about 1 mm to about 2 mm, or about 1.5 mm to about 3 mm. The maximum lateral dimension of the orifice 114 can affect the achievable resolution of the printed material and the rate at which the nozzle 100 can dispense the printing material. For example, increasing the maximum lateral dimension of the orifice 114 can increase the rate at which the nozzle 100 can dispense the printing material but may decrease the achievable resolution of the printing material.

[0039] The top surface 102 may exhibit a surface area of: about 0.075 mm 2 or greater, about 0.1 mm 2 or greater, about 0.2 mm 2 or greater, about 0.3 mm 2 or greater, about 0.5 mm 2 or greater, about 0.7 mm 2 or greater, about 1 mm 2 or greater, about 1.25 mm 2 or greater, about 1.5 mm 2 or greater, about 2 mm 2 or greater, about 3 mm 2 or greater, about 4 mm 2 or greater, or within the range of about 0.075 mm 2 to about 0.2 mm 2 about 0.1 mm 2 to about 0.3 mm 2 about 0.2 mm 2 to about 0.4 mm 2 about 0.3 mm 2 to about 0.5 mm 2 about 0.4 mm 2 to about 0.6 mm 2 about 0.5 mm2 to about 0.7 mm 2 、about 0.6 mm 2 to about 0.8 mm 2 、about 0.7 mm 2 to about 0.9 mm 2 、about 1 mm 2 to about 1.25 mm 2 、about 1 mm 2 to about 1.5 mm 2 、about 1.25 mm 2 to about 1.75 mm 2 、about 1.5 mm 2 to about 2 mm 2 、about 1.75 mm 2 to about 3 mm 2 、or about 2 mm 2 to about 4 mm 2 within the range of. In an example, the surface area of the top surface 102 can be selected based on the maximum lateral dimension of the orifice 114 because increasing the maximum lateral dimension of the orifice 114 can cause the surface area of the top surface 102 to increase. In an example, the surface area of the top surface 102 can be selected to be relatively small, thereby reducing the likelihood of contact between the top surface 102 and the printed material during use and / or reducing the adverse effects of contact between the top surface 102 and the printed material (e.g., soiling, dragging, or flattening).

[0040] In an embodiment, as shown, the top surface 102 can be substantially planar. In an embodiment, at least a portion of the top surface 102 can be non-planar, such as curved or tapered. The at least partially curved or tapered top surface 102 can reduce the likelihood of contact between the top surface 102 and the printed material during use. For example, the nozzle assembly (as Figures 11 to 13 shown) can extend in a manner that is not perpendicular to the printed material. The curved or tapered portion of the top surface 102 can prevent the following portions of the top surface 102 from contacting the printed material: If the top surface 102 were planar, these portions would protrude or be more likely to contact the printed material due to the non-perpendicular angle of the printing system relative to the printed material.

[0041] The bottom surface 104 is configured to contact one or more surfaces of the base ("base contact surfaces"). Examples of base contact surfaces are Figure 11The base contact surface 1142. The bottom surface 104 may exhibit a surface topography that generally corresponds to the base contact surface. For example, when the base contact surface is also generally planar, the bottom surface 104 may exhibit a generally planar topography. Selecting the bottom surface 104 to exhibit a surface topography that generally corresponds to the base contact surface can reduce the size of the gap that exists between the bottom surface 104 and the base contact surface. A gap that exists between the bottom surface 104 and the base contact surface may allow printing material to leak between the bottom surface 104 and the base contact surface. Leakage of the printing material between the bottom surface 104 and the bottom contact surface may cause material to be discharged from portions of the nozzle assembly other than the orifice 114. Leakage of the printing material between the bottom surface 104 and the bottom contact surface may also cause contamination of the printed material. For example, the leaked printing material may cure or be different in composition from the printing material that subsequently flows through the conduit 112, and mixing either the cured printing material or the printing material that is different in composition with the printing material that flows through the conduit 112 may cause printing defects. In an embodiment, the bottom surface 104 may be generally parallel to the top surface 102.

[0042] At least a portion of the side surface 106 is non-vertical (e.g., extends in a plane that intersects the central axis 118 of the nozzle 100). For example, when the side surface 106 is not parallel to (e.g., transverse to) the central axis 118 of the nozzle 100 (e.g., the axis extending from the center of the top surface 102 to the center of the bottom surface 104), the side surface 106 may be non-vertical. For example, at least about 55%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, about 100% (as shown), or in the range of about 55% to about 70%, about 60% to about 80%, about 70% to about 90%, or about 80% to about 100% of the side surface 106 is non-vertical. The non-vertical percentage of the side surface 106 may relate to any of the following: the percentage of at least one surface area in the surface area, the percentage of the length L along which the non-vertical side surface 106 of the nozzle 100 extends N of the nozzle 100, or the length of the side surface 106 measured along the shortest path from the top surface 102 to the bottom surface 104 (including or excluding any chamfered portions), and this shortest path extends along the non-vertical exterior of the side surface 106. Selecting the non-vertical percentage of the side surface 106 to be greater than 55% and further increasing the non-vertical percentage of the side surface 106 can facilitate attaching the nozzle 100 to the base. For example, as will be discussed in more detail below, the nozzle 100 may be positioned within a recess defined in the base and may be attached to the base. The recess may define a recess opening (e.g., after forging), and the recess opening is smaller than one or more dimensions of the nozzle 100 (e.g., smaller than the maximum lateral dimension D N) Thus, it is possible to prevent the nozzle 100 from leaving the recess and fix the nozzle 100 to the base. Increasing the non-vertical percentage of the side surface 106 can allow more of the side surface 106 to contact the surface of the base that defines the recess, thereby better fixing the nozzle 100 to the recess. Additionally, increasing the non-vertical percentage of the nozzle 100, such as increasing the portion of the nozzle 100 closer to the bottom surface 104, will increase the distance that the top surface 102 of the nozzle 100 can protrude from the base. Examples of the angle at which the side surface 106 can extend relative to the central axis 118 are disclosed in U.S. Provisional Patent No. 63 / 171,708, filed on April 7, 2021, the disclosure of which is incorporated herein by reference in its entirety.

[0043] In an embodiment, the side surface 106 includes a surface of a generally conical shape. However, the side surface 106 can include multiple surfaces or non-conical surfaces without limitation. In an example, the side surface 106 can include multiple surfaces, wherein the angle at which each surface of the side surface 106 extends relative to the central axis 118 can be different. The multiple side surfaces 106 can facilitate attaching the nozzle 100 to the base and can increase the distance that the top surface 102 of the nozzle 100 can extend above the base. In an example, at least a portion of the side surface 106 can exhibit a generally prismatic shape, a generally frustum shape, a generally cylindrical shape, or any other suitable shape.

[0044] As previously described, the nozzle 100 includes a chamfer portion 108 that extends from the bottom surface 104 to the side surface 106. Any of the chamfer portions disclosed herein includes one or more transitional surfaces between the other two surfaces, and unless otherwise disclosed herein, any of the chamfer portions disclosed herein can include one or more rounded surfaces (e.g., rounded surfaces having an average radius of curvature greater than about 0.025 mm, greater than about 0.05 mm, greater than about 0.1 mm, or greater than about 0.2 mm) and / or one or more planar surfaces. Compared with the insertion of the nozzle 100 when the nozzle 100 includes a sharp corner (e.g., a surface having an average radius of curvature less than 0.2 mm) between the bottom surface 104 and the side surface 106, the chamfer portion 108 can facilitate inserting the nozzle 100 into the recess defined by the base to which the nozzle 100 is attached.

[0045] At least a portion of at least one of the top surface 102, bottom surface 104, side surface, or any other outer surface (e.g., chamfer portion 108) of the nozzle 100 may be polished to exhibit a root mean square (“RMS”) surface roughness of about 3 μm or less, about 2 μm or less, about 1.5 μm or less, about 1 μm or less, about 750 nm or less, about 500 nm or less, about 300 nm or less, about 200 nm or less, about 100 nm or less, about 75 nm or less, about 50 nm or less, about 30 nm or less, about 15 nm or less, or from about 15 nm to about 50 nm, from about 30 nm to about 75 nm, from about 50 nm to about 100 nm, from about 75 nm to about 200 nm, from about 100 nm to about 300 nm, from about 200 nm to about 500 nm, from about 300 nm to about 750 nm, from about 500 nm to about 1 μm, from about 750 nm to about 1.5 μm, from about 1 μm to about 2 μm, from about 1.5 μm to about 3 μm. In an example, reducing the RMS surface roughness of at least a portion of the top surface 102 can reduce the coefficient of friction between the polished portion of the top surface 102 and the printed material. Thus, when the top surface 102 contacts the printed material, the polished portion of the top surface 102 is less likely to pull portions of the printed material in the direction in which the nozzle 100 moves relative to the printed material. In an example, contacting the polished portion of the top surface 102 with the printed material can cause the top surface 102 to impart a smooth surface to the printed material, which can be used to affect (e.g., improve) the deposition of the next layer of printed material on the printed material and / or can impart a desired shape to the printed material. In an example, polishing the bottom surface 104 and / or the side surface 106 to any of the RMS surface roughnesses described above can reduce the gap that might otherwise form between the bottom surface 104 and / or the side surface 106 and the base. Reducing the gap between the bottom surface 104 and / or the side surface 106 and the base can prevent or inhibit the leakage of printing material between the nozzle 100 and the base.

[0046] Referring Figure 1B , the conduit surface 110 includes a portion closest to the top surface 102 (“the top portion of the conduit surface”). The top portion of the conduit surface 110 includes a portion of the conduit surface 110 that extends a non-zero distance from the top surface 102 (e.g., the first conduit surface 110a) and / or a chamfer portion that extends between the top surface 102 and the conduit surface 110 (e.g., Figure 7 and Figure 8 the chamfer portion 724 or 824 shown in

[0047] A portion of the conduit surface 110 (e.g., the top or upper portion near the orifice 114) can be non-vertical (e.g., extending in a plane intersecting the central axis 118 of the nozzle 100). For example, the cross-section of the top portion of the conduit surface 110 is not parallel to (e.g., is set transverse to) the central axis 118 of the nozzle 100. In other words, this portion of the conduit surface 110 can extend laterally or radially inwards and / or laterally or radially outwards relative to the central axis 118. These portions of the conduit surface 110 that are set and extend at one or more inclined angles relative to the central axis 118 can define a surface that gradually expands or contracts the cross-sectional volume of the orifice 114.

[0048] Thus, the top portion of the conduit surface 110 may not exhibit a generally cylindrical shape or a generally rectangular shape because these shapes include vertical surfaces (e.g., aligned with the central axis 118). Surprisingly, it has been found that the non-verticality of the top portion of the conduit surface 110 can reduce the force required to push the printing material through the conduit compared to the force required to push the printing material through the conduit when the top portion of the conduit surface 110 is vertical. The non-verticality of the top portion of the conduit surface 110 allows the width of the conduit 112 (e.g., the width measured perpendicular to the central axis 118) to be reduced more gradually compared to when the top portion of the conduit surface 110 is vertical. It is currently believed that, at least to some extent, gradually reducing the width of the conduit 112 can reduce the force required to move the printing material through the conduit 112. Reducing the force required to push the printing material through the conduit 112 can also reduce the likelihood of the printing material leaking between the nozzle 100 and the base. It has also been surprisingly found that the non-verticality of the conduit 112 can reduce the likelihood of the conduit 112 becoming blocked when the printing material is flowing through the conduit 112.

[0049] In addition, unexpectedly, it has been found that the non-verticality of the top portion of the conduit surface 110 can permit more complete removal of the printing material from the conduit 112. For example, the printing material can be removed from the conduit 112 after completion of the printing process to prevent the printing material remaining in the conduit 112 from drying, solidifying, or clogging the conduit 112, thereby preventing further use of the nozzle 100. Alternatively or additionally, the printing material can be removed from the conduit 112 after printing of a first material through the nozzle 100 and before printing of a second material different from the first material through the nozzle 100 to prevent the first printed material from contaminating the second material. It has been found that when the top portion of the conduit surface 110 is vertical, removal of the printing material from the conduit 112 results in formation of a string of printing material that forms in and extends from the conduit 112. After removal of the remaining printing material, at least some of the strings of printing material in the string of printing material may remain in the conduit 112, and the strings of printing material remaining in the conduit 112 may be difficult to completely remove from the conduit 112. However, unexpectedly, it has been found that the non-verticality of the top portion of the conduit surface 110 prevents formation of a string of printing material, or at least reduces the amount of the string of printing material formed as compared to the amount of the string of printing material that would be formed when the top portion of the conduit surface 110 is vertical. In addition, if a string of printing material is formed during removal of the printing material, the non-verticality of the top portion of the conduit surface 110 permits removal of more of the string from the conduit 112 as compared to when the top portion of the conduit surface 110 is vertical. Without wishing to be bound by any theory, it is presently believed that when the conduit surface 110 includes a plurality of conduit surfaces, the intersections (i.e., corners or edges) between the different surfaces of the conduit surface 110 result in formation of the string. As compared to when the top portion of the conduit surface 110 is vertical, the non-verticality of the top portion of the conduit surface 110 can make the intersections between the different surfaces of the conduit surface 110 less pronounced (e.g., the difference between the angles θ and φ is smaller). It is believed that the less pronounced intersections formed due to the non-verticality of the top portion of the conduit surface 110 as compared to when the top portion of the conduit surface 110 is vertical reduce formation of the string and permit more complete removal of the printing material. It should be noted that the less pronounced intersections can also reduce the force required to push the printing material through the conduit 112 and reduce the likelihood of the printing material becoming clogged during operation.

[0050] As Figure 1B shown, the conduit surface 110 includes a first conduit surface 110a and a second conduit surface 110b. The first conduit surface 110a extends from the top surface 102 (as shown), or can extend from a chamfer portion that extends between the top surface 102 and the conduit surface 110a (asFigure 7 and Figure 8 extends to the second duct surface 110b (as shown). The second duct surface 110b extends from the first duct surface 110a towards the bottom surface 104 (e.g., extends to the bottom surface 104 as shown). The duct surface 110 is configured to include a plurality of surfaces such that the edges formed between these surfaces are less distinct. The duct surface will result in a less distinct edge being formed between the duct surface 110 and the bottom surface 104. Accordingly, the plurality of duct surfaces 110 can provide one or more of the following benefits: reducing the force required to push the printing material through the duct 112; reducing the likelihood that the printing material becomes clogged during operation; and / or preventing or reducing the likelihood of forming a printing material string when removing the printing material from the duct 112 as compared to the likelihood of forming a printing material string when the duct surface 110 includes only a single duct surface.

[0051] In the illustrated embodiment, the first duct surface 110a can at least partially form the top portion of the duct surface 110. Accordingly, the first duct surface 110a can be non-vertical. In an example, as shown, the first duct surface 110a can form a generally frustoconical shape. In such an example, the first duct surface 110a can extend at an angle θ with respect to the central axis 118. In an example, the first duct surface 110a can exhibit a generally converging shape (e.g., a generally tapered shape with curved sidewalls, such as forming concave or convex sidewalls when viewed in cross-section), a truncated generally polyhedral shape (e.g., the walls of the truncated generally polyhedral shape can extend at an angle θ with respect to the central axis 118), or any other suitable shape. It should be noted that, compared to when the first duct surface 110a exhibits intersecting surfaces, such as a frustoconical shape or a generally converging shape, the generally truncated generally polyhedral shape and other shapes of the first duct surface 110a can include intersecting surfaces that may increase the formation of printing material strings when removing the printing material. However, compared to when the first duct surface 110a exhibits a generally cylindrical shape or other shapes, the likelihood of these shapes forming printing material strings at such edges when removing the printing material is less.

[0052] It should be noted that, in some embodiments, the first duct surface 110a can exhibit a shape including a non-vertical surface and a vertical surface, such as a truncated generally triangular prism shape. Such shapes can increase (compared to a shape including only vertical surfaces) and decrease (compared to a shape not including vertical surfaces) the force required to push the printing material through the duct 112, the likelihood that the printing material becomes clogged, and / or the likelihood of forming a printing material string when removing the printing material from the duct 112.

[0053] When the first duct surface 110a extends at an angle θ relative to the central axis 118 (e.g., the first duct surface 110a presents a truncated generally conical or polyhedral shape), the angle θ can be selected to be about 1° or greater, about 2° or greater, about 3° or greater, about 4° or greater, about 5° or greater, about 6° or greater, about 7° or greater, about 8° or greater, about 9° or greater, about 10° or greater, about 12° or greater, about 14° or greater, about 18° or greater, about 20° or greater, about 25° or greater, about 30° or greater, about 35° or greater, about 40° or greater, about 45° or greater, or the angle θ can be selected to be in the range of about 1° to about 3°, about 2° to about 4°, about 3° to about 5°, about 4° to about 6°, about 5° to about 7°, about 6° to about 8°, about 7° to about 9°, about 8° to about 10°, about 9° to about 12°, about 10° to about 14°, about 12° to about 16°, about 14° to about 18°, about 16° to about 20°, about 18° to about 25°, about 20° to about 30°, about 25° to about 35°, about 30° to about 40°, or about 35° to about 45°. The angle θ can be selected based on one or more factors. In an example, the angle θ can be selected to be greater than about 4° because when the angle θ is less than 4°, the first duct surface 110a may start to behave similarly to a vertical duct surface. As used herein, the term "vertical" means that the angle θ is between 0° and 1°. In an example, the angle θ can be selected based on the method used to form the duct 112 because some methods of forming the duct 112 may only be able to form the first duct surface 110a at certain angles θ relative to the central axis 118. In an embodiment, the angle θ can be selected based on the angle φ at which the second duct surface 110b extends relative to the central axis 118 because typically the angle φ can be selected to be greater than the angle θ, thereby reducing the force required to push the printing material through the duct 112.

[0054] The second duct surface 110b can also be non-vertical, allowing the width of the duct 112 to generally decrease along the path of the duct 112 from the opening 116 to the orifice 114. In an example, the non-verticality of the second duct surface 110b can form a truncated generally conical shape. In such an example, the second duct surface 110b can extend at an angle φ relative to the central axis 118. In an example, the second duct surface 110b can present a generally converging shape, a truncated generally polyhedral shape, a generally truncated conical shape, or any other suitable shape. The second duct surface 110b can form a shape that is the same as or different from the shape formed by the first duct surface 110a.

[0055] When the second duct surface 110b extends at an angle φ relative to the central axis 118 (e.g., the second duct surface 110b presents a frustoconical or generally polyhedral shape), the angle φ can be selected to be about 5° or greater, about 6° or greater, about 7° or greater, about 8° or greater, about 9° or greater, about 10° or greater, about 12° or greater, about 14° or greater, about 18° or greater, about 20° or greater, about 25° or greater, about 30° or greater, about 35° or greater, about 40° or greater, about 45° or greater, about 50° or greater, about 55° or greater, about 60° or greater, about 65° or greater, about 70° or greater, or the angle φ can be selected to be in the range of about 5° to about 7°, about 6° to about 8°, about 7° to about 9°, about 8° to about 10°, about 9° to about 12°, about 10° to about 14°, about 12° to about 16°, about 14° to about 18°, about 16° to about 20°, about 18° to about 25°, about 20° to about 30°, about 25° to about 35°, about 30° to about 40°, about 35° to about 45°, about 40° to about 50°, about 45° to about 55°, about 50° to about 60°, about 55° to about 65°, or about 60° to about 70°. The angle φ can be selected based on one or more factors. In an example, the angle φ may depend on the angle θ of the first duct surface 110a because, as described above, the angle φ is selected to be greater than the angle θ. In an example, the angle φ can be selected such that the opening 116 presents a size comparable to the size of the channel at the base (e.g., Figure 11 the channel 1158). In such an example, the angle φ can also be selected based on the length L N of the nozzle 100 and the length along the central axis 118 of the first duct surface 110a because these factors may affect the angle φ required to form the opening 116 presenting a size comparable to the size of the channel at the base.

[0056] Figure 1C is an enlarged view of the portion of the nozzle 100 according to an embodiment located within Figure 1B the circle 1C shown in Figure 1CAs shown, the first duct surface 110a and the second duct surface 110b may be joined at the intersection 120. As previously described, when the printing material is removed from the duct 112, the intersection 120 may cause the formation of a filament of the printing material. The intersection 120 may be rounded so that the intersection 120 is less prominent and the likelihood of the intersection 120 causing the formation of a filament of the printing material when the printing material is removed from the duct 112 may be reduced compared to when the intersection 120 is not rounded. The intersection 120 may be rounded when the radius of curvature presented by the intersection 120 is any of the following: about 0.1 mm or greater, about 0.15 mm or greater, about 0.2 mm or greater, about 0.3 mm or greater, about 0.4 mm or greater, about 0.5 mm or greater, about 0.6 mm or greater, about 0.7 mm or greater, about 0.8 mm or greater, about 0.9 mm or greater, about 1 mm or greater, or within the range of about 0.1 mm to about 0.2 mm, about 0.15 mm to about 0.3 mm, about 0.2 mm to about 0.4 mm, about 0.3 mm to about 0.5 mm, about 0.4 mm to about 0.6 mm, about 0.5 mm to about 0.7 mm, about 0.6 mm to about 0.8 mm, about 0.7 mm to about 0.9 mm, 0.8 mm to about 1 mm. Generally, increasing the average radius of curvature of the intersection 120 may reduce the likelihood of the intersection 120 causing the formation of a filament of the printed material.

[0057] Figure 1D is an enlarged view of the portion of the nozzle 100 located within the circle 1C shown in Figure 1B As shown, the first duct surface 110a and the second duct surface 110b are joined at the unrounded intersection 120'. The intersection 120' is not rounded when the average radius of curvature presented by the intersection 120' is less than 0.1 mm. Compared to Figure 1D the intersection 120 shown in Figure 1C when the printing material is removed from the duct 112, the unrounded intersection 120' may increase the likelihood of the intersection 120' causing the formation of a filament of the printing material. However, compared to forming Figure 1C the intersection 120 shown in

[0058] The pipe surfaces disclosed herein may include three or more pipe surfaces, such as a first pipe surface, a second pipe surface, and at least one additional pipe surface (e.g., a third pipe surface). The first pipe surface may extend from or near the top surface of the nozzle to the second pipe surface, the second pipe surface may extend between the first pipe surface and the at least one additional pipe surface, and the at least one additional pipe surface may extend from the second pipe surface to or near the bottom surface. Figure 2 is a cross-sectional schematic view of a nozzle 200 according to an embodiment. Unless otherwise disclosed herein, the nozzle 200 may include one or more features that are the same as or substantially similar to any of the one or more features of other nozzle embodiments disclosed herein, without limitation. For example, the nozzle 200 may include a top surface 202, a bottom surface 204, at least one side surface 206, and a plurality of pipe surfaces 210 that define a pipe 212.

[0059] The pipe surfaces 210 of the nozzle 200 include a first pipe surface 210a, a second pipe surface 210b, and a third pipe surface 210c. The inclusion of the third pipe surface 210c further makes the edges formed between the pipe surfaces 210 less distinct, thereby reducing the amount of material filaments formed when removing the printing material and reducing the force required to push the printing material through the pipe 212.

[0060] The first pipe surface 210a extends from or near the top surface 202 at an angle θ with respect to the central axis 218. The second pipe surface 210b extends between the first pipe surface 210a and the third pipe surface 210c at an angle φ with respect to the central axis 218, and the angle φ is greater than the angle θ. The third pipe surface 210c extends from the second pipe surface 210c to the bottom surface 204 (e.g., extends to or near the bottom surface 204) at an angle α with respect to the central axis 218, and the angle α is greater than the angle φ. The angles θ, φ, and α may include any of the above angles.

[0061] It should be noted that the nozzle 200 may further include one or more additional pipe surfaces in addition to the first pipe surface 210a, the second pipe surface 210b, and the third pipe surface 210c. The one or more additional pipe surfaces may extend from the third pipe surface 210c to the bottom surface 204 (e.g., extend to or near the bottom surface 204). The additional pipe surfaces may further reduce the edges formed between the pipe surfaces 210, thereby reducing the amount of material filaments formed when removing the printing material and reducing the force required to push the printing material through the pipe 212.

[0062] As described above, the conduit surfaces disclosed herein may include curved surfaces, such as convex curved surfaces and concave curved surfaces. Figure 3 and Figure 4 respectively show cross-sectional views of different nozzle embodiments, each nozzle embodiment including a curved conduit surface. Unless otherwise disclosed herein, Figure 3 and Figure 4 the nozzles shown in may include one or more features that are the same as or substantially similar to any of the one or more features of the nozzles disclosed herein, without limitation. For example, a nozzle may include a top surface, a bottom surface, a side surface, and a conduit surface that defines a conduit.

[0063] Referring to Figure 3 , nozzle 300 may include a conduit surface 310 that exhibits a convex curvature. The convex curvature of the conduit surface 310 may be configured to allow the conduit surface 310 to have only one or more non-vertical surfaces at the top portion of the conduit surface 310. Thus, the conduit surface 310 may provide one or more of the following: a reduced likelihood of clogging the conduit 312 with printing material compared to when the conduit surface 310 includes a vertical surface; a reduced pressure required to push the printing material through the conduit 312; or a reduced likelihood of forming a string of printing material when removing the printing material from the conduit 312. In some embodiments, compared to the conduit surface 310 having a frustoconical shape as shown in Figure 1B and Figure 2 , the lateral dimensions at and near the opening 316 decrease at a greater rate. The greater change in the lateral dimensions at and near the opening 316 compared to when the conduit surface 310 has a frustoconical shape may increase the force required to move the printing material through the conduit 312 near the opening 316.

[0064] Referring to Figure 4 , nozzle 400 may include a conduit surface 410 that exhibits a concave curvature. The concave curvature of the conduit surface 410 may be configured to allow the conduit surface 410 to have only one or more non-vertical surfaces at the top portion of the conduit surface 410. Thus, the conduit surface 410 may provide one or more of the following: a reduced likelihood of clogging the conduit 412 with printing material compared to when the conduit surface 410 includes a vertical surface; a reduced pressure required to push the printing material through the conduit 412; or a reduced likelihood of forming a string of printing material when removing the printing material from the conduit 412. In some embodiments, compared to as shown in Figure 1B and Figure 2Compared with the frustoconical-shaped duct surface 410 shown in [reference], the lateral dimensions at and near the orifice 414 decrease at a greater rate. Compared with the frustoconical shape of the duct surface 410, the greater rate of change of the lateral dimensions at and near the orifice 414 may increase the force required to move the printing material through the duct 412 near the orifice 414.

[0065] During the operation of any of the nozzles disclosed herein, the printing material may be heated to maintain the printing material in a fluid (e.g., flowable) state and to control the viscosity of the printing material. The printing material may be heated by heating the nozzle, which in turn transfers heat to the printing material. It has been found that the effectiveness of the nozzle in heating the printing material flowing through the nozzle (e.g., minimizing the temperature gradient within the printing material) depends at least in part on the ratio of the surface area of the nozzle that is in direct contact with the printing material (e.g., the surface area of the orifice and the surface area of the duct surface) to the duct volume. In an example, increasing the surface area of the nozzle relative to the duct volume can make the heating of the printing material more effective (i.e., reduce the temperature to which the nozzle needs to be heated and / or reduce the temperature gradient within the printing material). In an example, reducing the surface area of the nozzle relative to the duct volume can reduce the efficiency of heating the printing material. In such an example, the nozzle 100 may need to be heated to a higher temperature to ensure that all of the printing material exhibits at least a certain temperature.

[0066] As Figure 1A shown, the orifice 114 may have a generally circular shape at or near the top surface 102. The duct 112 of the nozzle 100 may also have a generally circular shape when intersecting a reference plane oriented perpendicular to the central axis 118 ("in-plane shape") because forming the duct 112 and the orifice 114 to have the same general shape can facilitate the manufacture of the nozzle 100. The generally circular in-plane shape of the orifice 114 and the duct 112 of the nozzle 100 can reduce the surface area of the nozzle 100 that is in contact with the printing material relative to the volume of the duct 112 compared to a non-circular in-plane shape. Thus, in some embodiments, the nozzles disclosed herein may include an orifice and / or a duct having a non-circular in-plane shape to increase the ratio of the surface area of the nozzle that is in contact with the printing material to the duct volume. For example, Figure 5 and Figure 6Top views of nozzle 500 and nozzle 600 according to different embodiments, respectively. Both nozzle 500 and nozzle 600 have orifices presenting non-circular in-plane shapes. For example, nozzle 500 is shown to have an orifice 514 which presents an in-plane shape of a substantially hexagonal star with respect to the central axis 518, while nozzle 600 is shown to have an orifice 614 which presents an in-plane shape of a substantially pentagon with respect to the central axis 618. Although not shown, either the conduit 512 of nozzle 500 or the conduit 612 of nozzle 600 can respectively present any non-circular in-plane shape, such as an in-plane shape substantially similar to the shape of its orifice, for ease of manufacturing. Compared with the nozzle 100 shown in Figure 1A the non-circular in-plane shapes of the orifices 514, 614 and the conduits 512, 612 of nozzles 500, 600 can improve the effectiveness of nozzles 500, 600 in heating the printing material flowing through the nozzles 500, 600. It should be noted that the orifice and / or any orifice and / or conduit in any of the nozzles disclosed herein can present any non-circular in-plane shape (including an in-plane shape of a substantially hexagonal star or a substantially pentagon) without limitation, such as an in-plane shape of a substantially rectangle (e.g., oval), a substantially polygon, a substantially semi-circle, a substantially triangle, a substantially rectangle (e.g., square), a substantially hexagon, a substantially heptagon, a substantially octagon, a substantially four-pointed star, a substantially five-pointed star, or any other suitable non-circular in-plane shape.

[0067] As previously mentioned, the nozzles disclosed herein can include one or more chamfered portions that extend from the top surface to at least one of the side surface or the conduit surface. Figure 7 and Figure 8 are cross-sectional schematic views of different nozzles according to different embodiments. The nozzles all include chamfered portions that extend from their top surfaces to their side surfaces or conduit surfaces. Unless otherwise disclosed herein, Figure 7 and Figure 8 the nozzles shown in can include one or more features that are the same as or substantially similar to any of the features in other nozzle embodiments disclosed herein without limitation.

[0068] Referring to Figure 7, the nozzle 700 includes at least one outer chamfer portion 722 extending from a top surface 702 to a side surface 706. Compared with the case where the nozzle 700 does not include the outer chamfer portion 722, the outer chamfer portion 722 can prevent or at least reduce the possibility of interference between the nozzle 700 and the printed material. For example, for various reasons, such as the nozzle assembly including the nozzle 700 not extending in a manner completely parallel to the printed material or the thickness variation of the printed material, the top surface 702 of the nozzle 700 may not be oriented completely parallel to the printed material. In the case of a substantially similar nozzle without an outer chamfer portion, when the top surface of such a nozzle is not completely parallel to the printed material, a portion of the top surface of such a nozzle may eventually be closer to the printed material than the orifice of such a nozzle. The portion of the top surface closer to the printed material than the orifice may contact or interfere with the printed material because the orifice of the nozzle may be configured to be positioned near the printed material to improve the resolution of the printed material. The contact between the top surface of the nozzle and the printed material may cause at least one of the following: deforming the printed material (e.g., scratching or scuffing), removing or reducing one or more adhesion features (e.g., a polished surface, one or more grooves, or one or more protrusions) formed on the printed material, or possibly pulling the printed material in the direction of movement of the nozzle (relative to the printed material). However, when the top surface 702 is not completely parallel to the printed material, the outer chamfer portion 722 of the nozzle 700 reduces the maximum distance that the top surface 702 of the nozzle 700 can extend beyond the orifice 714 of the nozzle 700. The reduction in the maximum distance that the top surface 702 extends beyond the orifice 714 can prevent or at least reduce the possibility that the top surface 702 will contact or interfere with the printed material.

[0069] The outer chamfer portion 722 may exhibit a width W measured perpendicular to the central axis 718 of the nozzle C and a length L measured parallel to the central axis 718 C . The width W C and the length L Ccan be independently selected to be about 0.05 mm or greater, about 0.075 mm or greater, about 0.1 mm or greater, about 0.125 mm or greater, about 0.15 mm or greater, about 0.2 mm or greater, about 0.25 mm or greater, about 0.3 mm or greater, about 0.4 mm or greater, about 0.5 mm or greater, about 0.6 mm or greater, about 0.7 mm or greater, about 0.8 mm or greater, about 0.9 mm or greater, about 1 mm or greater, or can be independently selected to be in the range of about 0.05 mm to about 0.1 mm, about 0.075 mm to about 0.125 mm, about 0.1 mm to about 0.15 mm, about 0.125 mm to about 0.2 mm, about 0.15 mm to about 0.25 mm, about 0.2 mm to about 0.3 mm, about 0.25 mm to about 0.4 mm, about 0.3 mm to about 0.5 mm, about 0.4 mm to about 0.6 mm, about 0.5 mm to about 0.7 mm, about 0.6 mm to about 0.8 mm, about 0.7 mm to about 0.9 mm, or about 0.8 mm to about 1 mm.

[0070] Width W C and length L C can be selected based on one or more factors. In an example, width W C and length L C can be selected based on the overall width and overall length of nozzle 700, where the overall width and overall length are measured perpendicular to width W C and length L C respectively. In an example, width W C and length L C can be selected based on one or more angles at which side surface 706 extends relative to central axis 718, because the one or more angles can affect the angle at which outer chamfer portion 722 extends relative to central axis 718. In an example, width W C and length L C can be selected based on the hardness of nozzle 700, and more particularly, width W C and length L C can be selected based on the difficulty of forming, grinding, or machining nozzle 700. For example, nozzle 700 can be formed of PCD, PcBN, or other superhard materials that are difficult to form, grind, or machine. Thus, width W C and length L C can be selected to be as large as needed only, to avoid excessive manufacturing time, tools, and / or associated costs.

[0071] The top surface 702 may present a first surface area, while the outer chamfer portion 722 may present a second surface area. In an embodiment, the second surface area of the outer chamfer portion 722 may be selected to be significantly smaller than the first surface area of the top surface 702 (e.g., about 1% to about 10%, about 5% to about 15%, about 10% to about 20%, or about 15% to about 25% smaller) (e.g., to reduce the machining of the nozzle 700). In an embodiment, the second surface area of the outer chamfer portion 722 may be selected to be comparable to or larger than the first surface area of the top surface 702 (e.g., about 80% to about 100%, about 90% to about 120%, about 100% to about 150%, or greater than 150%). Such a configuration can significantly reduce the likelihood of the nozzle 700 coming into contact with the printed material. In an embodiment, the second surface area of the outer chamfer portion 722 may be about 25% to about 80% of the first surface area of the top surface 702.

[0072] The nozzle 700 may include an inner chamfer portion 724 extending from the top surface 702 to the conduit surface 710. The inner chamfer portion 724 may increase the maximum lateral dimension (e.g., diameter) of the conduit 712 at the orifice 114. Increasing the maximum lateral dimension of the conduit 712 at the orifice 714 by the inner chamfer portion 724 can improve the consistency of the printed material dispensed through the nozzle 700 (e.g., reduce the variation in one or more lateral dimensions of the printed material), thereby improving the resolution of the printed material. The inner chamfer portion 724 may present a width and a length measured perpendicular and parallel to the central axis 718, respectively, and the width and length are within any of the ranges discussed above for the width W C and L C discussed.

[0073] The outer chamfer portion 722 and the inner chamfer portion 724 are shown as generally conical surfaces. However, the nozzles disclosed herein may include inner and outer chamfer portions presenting generally the following surfaces: curved surfaces, dome surfaces, convex surfaces, concave surfaces, oval surfaces, annular surfaces, or spherical surfaces. For example, referring to Figure 8 , the nozzle 800 includes an outer chamfer portion 822 extending from the top surface 802 to the side surface 806 and an inner chamfer portion 824 extending from the top surface 802 to the conduit surface 810. The outer chamfer portion 822 and the inner chamfer portion 824 may present one or more features that are the same as or substantially similar to one or more features of the outer chamfer portion 722 or the inner chamfer portion 724 shown in Figure 7 , except that the outer chamfer portion 822 and the inner chamfer portion 824 include convex curved surfaces (when viewed in a cross-sectional view).

[0074] It is currently believed that, compared to the curved or annular outer chamfer portion 822, the generally conical outer chamfer portion 722 can reduce the likelihood of the nozzle 700 contacting the printed material, because the slope of the conical outer chamfer portion 722 adjacent to the top surface 702 is greater than the slope of the curved outer chamfer portion 822 adjacent to the top surface 802. It is currently believed that, compared to Figure 7 the conical inner chamfer portion 724 shown in Figure 8 the curved inner chamfer portion 824 shown in

[0075] Figure 7 and Figure 8 the nozzles 700 and 800 of

[0076] are shown as including only the conical chamfer portion or the curved chamfer portion extending from the top surface of the nozzles 700 and 800. However, it should be noted that the nozzles disclosed herein may include a curved outer chamfer portion and a conical inner chamfer portion or a conical outer chamfer portion and a curved inner chamfer portion. In addition, it should be noted that the nozzles disclosed herein may include only one of the outer chamfer portion or the inner chamfer portion or neither the outer chamfer portion nor the inner chamfer portion. Figure 9A and Figure 10 are cross-sectional schematic views of nozzles 900, 1000 according to different embodiments, which are configured to increase the surface area of the printed material thus formed. Unless otherwise disclosed herein, Figure 9A and Figure 10 the nozzles 900, 1000 shown in

[0077] Referring to Figure 9A, the nozzle 900 includes at least one top surface 902, at least one side surface 906, and at least one duct surface 910. The nozzle 900 includes (e.g., defines) one or more channels 926 that extend inwardly from the top surface 902. The channels 926 are configured to form one or more protrusions in the printed material, thereby increasing the surface area of the printed material, which, as described above, can enhance the adhesion to subsequent printed material layers deposited on the printed material. When at least one of the printed materials brushes against the channels 926 when being dispensed through the nozzle 900, or when the top surface 902 can contact the printed material after the printed material is deposited, the channels 926 can form protrusions in the printed material.

[0078] The nozzle 900 can include any number of channels 926 formed thereon. For example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more than 10 channels 926 can be formed on the nozzle 900. The number of channels 926 can affect at least one of the following: the number of protrusions formed in the printed material, the size of the channels 926 formed on the nozzle 900 (which determines the size of the protrusions formed in the printed material), or the number of directions in which the nozzle 900 can move relative to the printed material.

[0079] In an embodiment, as shown, the channels 926 can be radially extending channels 926 that extend from the duct surface 910 to the side surface 906. In this embodiment, only the channels 926 that extend substantially parallel to the direction in which the nozzle 900 moves during operation can form protrusions in the printing material. In another embodiment (not shown), the channels can include a plurality of substantially parallel channels. In this embodiment, the substantially parallel channels can be oriented substantially parallel to the direction of relative movement between the nozzle 900 and the printed material during operation, thereby allowing more protrusions to be formed in the printed material compared to the case where each of the channels is a radially extending channel 926. In a further embodiment, the printing device to which the nozzle 900 is attached (e.g., via a base) can be configured to rotate the nozzle 900 such that the channels can be oriented in a selected orientation relative to the expected relative movement direction between the nozzle 900 and the printed material. Rotating the nozzle 900 can allow one or more of the radially extending channels 926 or a plurality of substantially parallel channels (not shown) to be generally parallel to the expected relative movement direction between the nozzle 900 and the printed material. The printing device can be configured to rotate the nozzle 900 such that one or more of the channels 926 are oriented generally parallel to the direction of movement between the nozzle 900 and the printed material.

[0080] Figure 9Bis an enlarged cross-sectional schematic view of a portion including channel 926 taken from the circle 9B shown in Figure 9A . As shown in Figure 9B , channel 926 may exhibit a width W measured between opposite portions defining the channel 926 on the top surface 902 R and a maximum depth D measured perpendicular to the width W R . The width W R and the maximum depth D may be independently selected to be about 0.05 mm or greater, about 0.075 mm or greater, about 0.1 mm or greater, about 0.125 mm or greater, about 0.15 mm or greater, about 0.2 mm or greater, about 0.25 mm or greater, about 0.3 mm or greater, about 0.4 mm or greater, about 0.5 mm or greater, about 0.6 mm or greater, about 0.7 mm or greater, about 0.8 mm or greater, about 0.9 mm or greater, about 1 mm or greater, or may be independently selected to be in the range of about 0.05 mm to about 0.1 mm, about 0.075 mm to about 0.125 mm, about 0.1 mm to about 0.15 mm, about 0.125 mm to about 0.2 mm, about 0.15 mm to about 0.25 mm, about 0.2 mm to about 0.3 mm, about 0.25 mm to about 0.4 mm, about 0.3 mm to about 0.5 mm, about 0.4 mm to about 0.6 mm, about 0.5 mm to about 0.7 mm, about 0.6 mm to about 0.8 mm, about 0.7 mm to about 0.9 mm, or about 0.8 mm to about 1 mm. The width W R and the depth D may be selected based on the desired dimensions of the protrusions formed in the printed material, since such protrusions may exhibit dimensions corresponding to the dimensions of the channel 926. The desired dimensions of the protrusions may be selected based on one or more materials forming the printed material. For example, one or more of the width W R or the depth D of the channel 926 may be selected to increase the surface area of the protrusions, which may be beneficial when one or more of the materials forming the printed material exhibit poor adhesion.

[0081] Channel 926 may be defined by one or more channel surfaces 928. In an example, channel 926 may exhibit a generally rectangular (e.g., square) cross-sectional shape. In such an example, the channel surfaces 928 defining the channel 926 may include two generally vertical channel surfaces extending inwardly from the top surface 902 and a generally horizontal channel surface extending between the vertical surfaces. It should be noted that the channels formed in any of the nozzles disclosed herein may exhibit a non-rectangular cross-sectional shape. For example, Figure 9C and Figure 9DIt is an enlarged cross-sectional schematic view of parts of nozzles 900c and 900d respectively including channels 926c and 926d according to different embodiments. Unless otherwise disclosed herein, one or more features of nozzle 900c or nozzle 900d may be the same as or substantially similar to one or more features of nozzle 900. As shown, nozzle 900c includes a channel 926c extending inwards from the top surface 902c, and the channel 926c presents a generally triangular cross-sectional shape, while nozzle 900d includes a channel 926d extending inwards from the top surface 902d, and the channel 926d presents a generally semi-circular cross-sectional shape. For example, the cross-sectional shape of the channel can be selected based on one or more materials forming the printed material. For example, different cross-sectional shapes of the channel may affect the surface area of the printed material, and / or compared with other cross-sectional shapes, certain cross-sectional shapes of the channel may more improve the adhesion between the one or more materials.

[0082] Referring to Figure 10 , nozzle 1000 includes one or more protrusions 1030 extending upward from the top surface 1002 of nozzle 1000. Optionally, the protrusions 1030 can be configured to form one or more recesses in the printed material, thereby increasing the surface area of the printed material, as previously described, which can enhance the adhesion to subsequent printed material layers deposited on the printed material. For example, the protrusions 1030 can form recesses in the printed material when at least one of the following occurs: 1) the printed material brushes against the protrusions 1030 when being dispensed through nozzle 1000; or the top surface 1002 comes into contact with the printed material after the printed material is deposited.

[0083] The protrusions 1030 can include one or more features that are the same as or substantially similar to one or more features of the channel 926, except that the protrusions 1030 extend outward from the top surface 1002 instead of inward. In an example, nozzle 1000 can include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more than 10 protrusions 1030 formed thereon. In an example, the protrusions 1030 can include a plurality of radially extending protrusions 1030 or a plurality of parallel protrusions 1030. In any embodiment, the printing device to which nozzle 1000 is attached (e.g., via a base) can be configured to rotate nozzle 1000. In an example, the protrusions 1030 can present a width W independently selected from the channels 926 discussed above RWidth and maximum height within any range in the range of the sum and maximum depth D. The width and maximum height of the protrusion 1030 can be selected based on the desired dimensions of the recess formed in the printed material, as such a recess can exhibit dimensions corresponding to those of the protrusion 1030. In an example, the protrusion 1030 can exhibit a cross-sectional shape that is generally rectangular (e.g., square), generally triangular, generally semi-circular, or any other suitable cross-sectional shape. The cross-sectional shape of the protrusion 1030 can be selected based on one or more materials forming the printed material, as different cross-sectional shapes of the protrusion 1030 may affect the surface area of the printed material, and / or certain cross-sectional shapes of the protrusion can improve the adhesion between the one or more materials more than other cross-sectional shapes.

[0084] As previously described, the nozzles disclosed herein can be attached to a base to form a nozzle assembly that is configured to be attached to a printing device. Figure 11 is a cross-sectional schematic view of a nozzle assembly 1132 according to an embodiment, the nozzle assembly 1132 including a nozzle 1100 attached to a base 1134. Unless otherwise disclosed herein, the nozzle 1100 can include one or more features that are the same as or substantially similar to one or more features of any of the nozzles disclosed herein, without limitation.

[0085] The base 1134 includes a nozzle portion 1136 and an attachment portion 1138, the nozzle portion 1136 being configured to attach the nozzle 1100 to the nozzle portion 1136, the attachment portion 1138 being configured to attach the base 1134 to a printing device (not shown). Optionally, the base 1134 can include an intermediate portion 1140 between the nozzle portion 1136 and the attachment portion 1138.

[0086] The nozzle portion 1136 of the base 1134 defines a recess (not labeled, which is occupied by the nozzle 1100), and the recess is configured to receive the nozzle 1100. The recess portion is defined by a base contact surface 1142, and the base contact surface 1142 is configured to abut against the bottom surface 1104 of the nozzle 1100. The base contact surface 1142 may exhibit a surface topography that generally corresponds to the surface topography of the bottom surface 1104 of the nozzle 1100. The corresponding surface topographies of the base contact surface 1142 and the bottom surface 1104 may be configured to prevent or at least inhibit leakage of the printing material between the nozzle 1100 and the base 1134. The recess is also partially defined by at least one recess side surface 1144. The recess side surface 1144 may define a recess opening 1146 that allows the orifice 1114 of the nozzle 1100 to be exposed (e.g., not covered by the base 1134), and may allow a portion of the nozzle 1100 to extend beyond the end surface of the base 1134. In other words, the recess side surface 1144 may be configured not to abut against or cover at least a portion (e.g., all) of the top surface 1102 of the nozzle 1100. The recess side surface 1144 may exhibit a shape that corresponds to the shape of the side surface 1106 of the nozzle 1100, thereby preventing or at least inhibiting leakage of the printing material between the recess side surface 1144 and the side surface 1106 of the nozzle 1100. Optionally, the recess may include at least one chamfered surface (not shown) that extends between the base contact surface 1142 and the recess side surface 1144, and the chamfered surface is sized and configured to abut against an optional chamfered portion (not shown) of the nozzle 1100 of the nozzle 1100: the optional chamfered portion extends between the bottom surface 1104 and the side surface 1106 of the nozzle 1100.

[0087] The nozzle portion 1136 may include at least one wall 1148 extending from the remainder of the nozzle portion 1136 (e.g., the tapered surface 1150 or the gripping feature). The wall 1148 forms at least a part of the recess side surface 1144. In one embodiment, the wall 1148 may be configured to allow the base 1134 to fix the nozzle 1100 to the base 1134 via forging. For example, the wall 1148 may initially be vertical or otherwise oriented (not shown) such that the lateral dimension of the recess opening 1146 is wide enough for the nozzle 1100 to be correctly positioned in the recess (e.g., the bottom surface 1104 of the nozzle 1100 abuts the base contact surface 1142). The wall 1148 may be configured to deform inwardly, thereby reducing the lateral dimension of the recess opening 1146 such that the lateral dimension of the recess opening 1146 is not wide enough for the nozzle 1100 to pass through the recess opening 1146. Thus, the inward deformation of the wall 1148 may fix and / or position the nozzle 1100 to the base 1134. The wall 1148 may also deform inwardly such that the recess side surface 1144 abuts the lateral surface 1106 of the nozzle 1100.

[0088] The nozzle portion 1136 may include a tapered surface 1150 extending outwardly from the recess opening 1146 and / or the wall 1148. The tapered surface 1150 may include one or more planar surfaces and / or rounded surfaces. As Figure 11 shown, the tapered surface 1150 is not perpendicular to the longitudinal axis of the base 1134 (e.g., with respect to the central axis, not shown), but is angled and / or curved toward the attachment portion 1138 of the base 1134. Compared with the base 1134 including a non-tapered surface, the tapered surface 1150 may prevent or at least reduce the possibility of the base 1134 coming into contact with the printed material.

[0089] The nozzle portion 1136 may include one or more gripping features configured to facilitate the attachment and separation of the base 1134 to and from the printing device. In an embodiment, as described below, the nozzle portion 1136 may be configured to be attached to the printing device (not shown) in a threaded manner and may include a "wrench plane" sized and configured to allow a wrench to rotate the nozzle assembly. In some embodiments, the gripping feature may include a generally square, hexagonal (as shown), other suitable wrench plane shape, or other suitable shape to allow a finger, pliers, wrench, socket, or other tool to grip and twist a portion of the nozzle portion 1136. In some embodiments, the gripping feature may include one or more textured surfaces (cylindrical, wrench plane, or other suitable shape) or high friction material, thereby also allowing a finger, pliers, or other tool to grip the nozzle portion 1136.

[0090] As described above, the base 1134 includes an attachment portion 1138. The attachment portion 1138 is configured to attach the base 1134 to a printing device. In an embodiment, as shown, the attachment portion 1138 is configured to attach to the printing device in a threaded manner. In such an embodiment, the attachment portion 1138 may be defined with one or more helically extending threaded portions 1154. In an embodiment, the attachment portion 1138 may include a magnet, a recess configured to receive a pin, or the attachment portion 1138 may be configured to be press-fitted to the printing device, or the attachment portion 1138 may be configured to be brazed to the printing device, soldered to the printing device, attached to the printing device in an adhesive manner, or attached to the printing device using any other suitable technique. In an embodiment, the base 1134 may be configured to selectively attach to and remove from the printing device, respectively. In such an embodiment, the base 1134 may be attached to and detached from the printing device with substantially no damage to the base 1134 or the printing device. Selectively attaching the base 1134 to the printing device allows the printing device to be used with various nozzle assemblies (e.g., nozzle assemblies having different sized orifices), or allows for replacement of a worn nozzle assembly. In an embodiment, the base 1134 may be configured to selectively attach to itself.

[0091] The base 1134 includes at least one channel surface 1156 that defines a channel 1158. The channel 1158 is configured to extend from a conduit (e.g., an opening of the conduit) of the nozzle 1100 to the exterior of the base. When the base 1134 is attached to the printing device, the channel 1158 may be in fluid communication with a printing material source (e.g., another conduit or a tank) of the printing device. Thus, printing material from the printing material source may flow through the channel 1158 and to the conduit 1112 of the nozzle 1100. In an embodiment, the channel 1158 is centrally located within the base 1134 and extends from the base contact surface 1142 to an opposite surface of the attachment portion 1138. However, it should be noted that the channel 1158 may not exhibit one or more of the following characteristics: being centrally located, extending from the base contact surface, or extending to an opposite surface of the attachment portion 1138 (e.g., depending on the location of the printing material source and / or the location of the opening of the conduit of the nozzle 1100).

[0092] As described above, the nozzle 1100 may be fixed to the base 1134 via forging or other suitable deformation of the base 1134 to achieve retention of the nozzle 1100. However, one or more other techniques such as brazing, soldering, adhesive bonding, press fitting, threaded attachment, etc. may be used to fix the nozzle 1100 to the base 1134, or otherwise attach the nozzle 1100 to the base 1134. Depending on the one or more methods used to attach the nozzle 1100 to the base 1134, the recess may be omitted from the base 1134, and the nozzle 1100 may be attached only to the outer surface of the base 1134. Additional examples of attaching the nozzle 1100 to the base 1134 are disclosed in U.S. Provisional Patent Application No. 63 / 171,708, filed on April 7, 2021, the disclosure of which is incorporated herein by reference in its entirety. It should be noted that when the nozzle 1100 includes PCD, the one or more methods used to attach the nozzle 1100 to the base 1134 may be selected to include one or more non-thermal attachment techniques (thermal attachment techniques being attachment techniques that require heating of the nozzle 1100), or attachment techniques that heat the nozzle 1100 to a temperature of up to 700 °C, because PCD may begin to degrade when exposed to temperatures above 700 °C.

[0093] As described above, the top surface 1102 of the nozzle 1100 can extend a distance d above the base 1134. Extending the top surface 1102 above the base 1134 reduces the likelihood that the base 1134 contacts the printed material, thereby soiling, displacing, or otherwise adversely affecting the printed material. In an embodiment, the distance d can be selected to be greater than about 0.1 mm, greater than about 0.5 mm, greater than about 1 mm, greater than about 1.5 mm, greater than about 2 mm, greater than about 2.5 mm, greater than about 3 mm, greater than about 3.5 mm, greater than about 4 mm, greater than about 5 mm, or the distance d can be selected to be in the range of about 0.1 mm to about 0.5 mm, about 0.25 mm to about 0.75 mm, about 0.5 mm to about 1 mm, about 0.75 mm to about 1.25 mm, about 1 mm to about 1.5 mm, about 1.25 mm to about 1.75 mm, about 1.5 mm to about 2 mm, about 1.75 mm to about 2.25 mm, about 2 mm to about 2.5 mm, about 2.25 mm to about 2.75 mm, about 2.5 mm to about 3 mm, about 2.75 mm to about 3.25 mm, about 3 mm to about 3.5 mm, about 3.25 mm to about 3.75 mm, about 3.5 mm to about 4 mm, about 3.75 mm to about 4.5 mm, or about 4 mm to about 5 mm. In an embodiment, the ratio of the distance d to the maximum length of the nozzle 1100, calculated using the formula d / (maximum length), is about 0.1 to about 0.3, about 0.2 to about 0.4, about 0.3 to about 0.5, about 0.4 to about 0.6, about 0.5 to about 0.7, about 0.6 to about 0.8, or about 0.7 to about 0.9. The distance d and the ratio of the distance d to the maximum length can be selected based on: the maximum length of the nozzle 1100, the non-vertical percentage of the side surface 1106, the angle of the non-vertical portion of the nozzle 1100 relative to the central axis of the nozzle 1100, and the desired resolution of the printed material.

[0094] As described above, the nozzle 1100 can be heated during operation to control the temperature of the printing material (e.g., to keep the printing material in a fluid state and / or to control the viscosity of the printing material). Generally, heating the nozzle 1100 includes heating the base 1134 with a printing device, transferring heat from the base 1134 to the nozzle 1100, and transferring heat from the nozzle 1100 to the printing material. The thermal conductivities of the nozzle 1100 and the base 1134 affect how effectively and consistently the printing material is heated. For example, reducing the thermal conductivities of the nozzle 1100 and the base 1134 causes the portions of the nozzle 1100 and the base 1134 closest to the heater of the printing device to exhibit a higher temperature than the portions of the nozzle 1100 and the base 1134 spaced apart from the heating device. Depending on which part of the nozzle assembly 1132 the printing material flows through, this temperature gradient causes the printing material to be heated to different temperatures. Different temperatures may cause portions of the printing material to be heated to too low a temperature to keep the printing material in a fluid state or maintain the viscosity of the printing material, and / or may require portions of the printing material to be heated to too high a temperature (which may cause the printing material to burn). Thus, it is beneficial to select materials for the nozzle 1100 and the base 1134 to increase their thermal conductivities, thereby reducing any temperature gradient in the nozzle 1100 and the base 1134.

[0095] In an embodiment, the nozzle 1100 can be formed of PCD or PcBN, which materials exhibit extremely high thermal conductivities and wear resistances. In such an embodiment, the base 1134 can be formed of a material having a lower thermal conductivity than PCD and PcBN, such as brass or steel. The volume of the nozzle 1100 can be increased to mitigate the effect of the lower thermal conductivity of the base 1134. For example, at least some conventional superhard nozzles exhibit a volume of about 6.5 mm 3 or less. The nozzle 1100 (and any of the nozzles disclosed herein) can exhibit a volume of: about 7.5 mm 3 or greater, about 8 mm 3 or greater, about 9 mm 3 or greater, about 10 mm 3 or greater, about 11 mm 3 or greater, about 12 mm 3 or greater, about 13 mm 3 or greater, about 15 mm 3 or greater, about 17.5 mm 3 or greater, about 20 mm 3 or greater, about 22.5 mm 3 or greater, about 25 mm 3 or greater, about 30 mm 3 or greater, about 35 mm 3or greater, about 40 mm 3 or greater, about 40 mm 3 or greater, about 45 mm 3 or greater, about 50 mm 3 or greater, about 60 mm 3 or greater, about 70 mm 3 or greater, about 80 mm 3 or greater, about 90 mm 3 or greater, about 100 mm 3 or greater, about 250 mm 3 or greater, about 500 mm 3 or greater, about 750 mm 3 or greater, about 1,000 mm 3 or greater, about 2,500 mm 3 or greater, about 5,000 mm 3 or greater, about 7,500 mm 3 or greater, or at about 7.5 mm 3 to about 9 mm 3 about 8 mm 3 to about 10 mm 3 about 9 mm 3 to about 11 mm 3 about 10 mm 3 to about 12 mm 3 about 11 mm 3 to about 13 mm 3 about 12 mm 3 to about 14 mm 3 about 13 mm 3 to about 15 mm 3 about 14 mm 3 to about 17.5 mm 3 about 15 mm 3 to about 20 mm 3 about 17.5 mm 3 to about 22.5 mm 3 about 20 mm 3 to about 25 mm 3 about 22.5 mm 3 to about 30 mm 3 about 25 mm 3 to about 35 mm 3 about 30 mm 3 to about 40 mm 3 about 35 mm 3 to about 45 mm 3 about 40 mm 3 to about 50 mm 3 about 45 mm3 to about 60 mm 3 and about 50 mm 3 to about 70 mm 3 and about 60 mm 3 to about 80 mm 3 and about 70 mm 3 to about 90 mm 3 and about 80 mm 3 to about 100 mm 3 and about 90 mm 3 to about 250 mm 3 and about 100 mm 3 to about 500 mm 3 and about 250 mm 3 to about 750 mm 3 and about 500 mm 3 to about 1,000 mm 3 and about 750 mm 3 to about 2,500 mm 3 and about 1,000 mm 3 to about 5,000 mm 3 or about 2,500 mm 3 to about 7,500 mm 3 within the range of

[0096] In an embodiment, the maximum lateral dimension D that the nozzle 1100 can exhibit N is less than the maximum lateral dimension D of the base 1134 B , thereby facilitating the attachment of the nozzle 1100 to the base 1134 using die forging or the recess defined by the base 1134. However, in such an embodiment, the smaller maximum lateral dimension D of the nozzle 1100 N limits the volume exhibited by the nozzle 1100. In other words, when the nozzle 1100 is formed of PCD or PcBN, the smaller maximum lateral dimension D of the nozzle 1100 N can reduce the effect of the high thermal conductivity of the nozzle 1100. In an embodiment, the maximum lateral dimension that the nozzles disclosed herein can exhibit is equal to or greater than the maximum lateral dimension of the base to which the nozzle is attached. In such an embodiment, the maximum lateral dimension exhibited by the nozzle is equal to or greater than the maximum lateral dimension of the base to which the nozzle is attached, thereby allowing an increase in the volume of the nozzle. For example, Figure 12 is a cross-sectional schematic view of a nozzle assembly 1232 according to an embodiment, the nozzle assembly 1232 including a nozzle 1200 attached to a base 1234, wherein the maximum lateral dimension D N is equal to or greater than the maximum lateral dimension D of the base 1234 BUnless otherwise disclosed herein, one or more features of the nozzle 1200 or the base 1234 may be the same as or substantially similar to one or more features of any of the nozzles and bases disclosed herein.

[0097] The maximum lateral dimension D of the nozzle 1200 N may impede the use of certain attachment techniques (e.g., die forging) and / or the use of recesses to attach the nozzle to the base 1234, or may complicate the use of certain attachment techniques (e.g., die forging) and / or the use of recesses to attach the nozzle to the base 1234. Instead, in embodiments, the nozzle 1200 may be brazed, soldered, adhesively attached to the base 1234, or otherwise attached to the base 1234 using any suitable technique. In embodiments, the nozzle 1200 may include a protrusion extending from its bottom surface, the protrusion being configured to be positioned in a recess defined by the base 1234. An example of a protrusion extending from the bottom surface of a PCD body is disclosed in U.S. Provisional Patent Application No. 63 / 154,277, filed on February 26, 2021, the disclosure of which is incorporated herein by reference in its entirety.

[0098] The nozzle 1200 may exhibit any of the volumes discussed above with respect to Figure 11 the nozzle 1100 shown in 3 However, it should be noted that the nozzle 1200 may exhibit a volume of about 150 mm 3 or greater, about 200 mm 3 or greater, about 300 mm 3 or greater, about 400 mm 3 or greater, about 500 mm 3 or greater, about 1 cm 3 or greater, about 1.25 cm 3 or greater, about 1.5 cm 3 or greater, about 1.75 cm 3 or greater, about 2 cm 3 or greater, about 2.25 cm 3 or greater, about 2.5 cm 3 or greater, about 3 cm 3 or greater, about 4 cm 3 or greater, about 5 cm 3 or greater, or a volume between about 100 mm 3 and about 200 mm 3 about 150 mm 3 and about 300 mm 3 about 200 mm 3 and about 400 mm3 、About 300 mm 3 to about 500 mm 3 、About 400 mm 3 to about 750 mm 3 、About 500 mm 3 to about 1 cm 3 、About 750 mm 3 to about 1.25 cm 3 、About 1 cm 3 to about 1.5 cm 3 、About 1.25 cm 3 to about 1.75 cm 3 、About 1.5 cm 3 to about 2 cm 3 、About 1.75 cm 3 to about 2.5 cm 3 、About 2 cm 3 to about 3 cm 3 、About 2.5 cm 3 to about 4 cm 3 、Or about 3 cm 3 to about 5 cm 3 within the range of.

[0099] In some embodiments, the nozzle disclosed herein may form the entire nozzle assembly. For example, Figure 13 is a cross-sectional schematic view of a nozzle assembly 1332 according to an embodiment that includes a nozzle 1300 but does not include a base. Since the nozzle 1300 forms the entire nozzle assembly 1332 (or most of the nozzle assembly 1332 or substantially the entire nozzle assembly 1332), the thermal conductivity of the nozzle 1300 can control the heating of the printing material. In this configuration, the nozzle 1300 may include one or more superhard materials without limitation. In one embodiment, when the nozzle 1300 is formed of PCD or PcBN, the high thermal conductivity of these materials can cause at least a portion of the nozzle 1300 to be heated to substantially the same temperature (e.g., any temperature gradient in the nozzle 1300 may be less than 1 °C, less than 2 °C, or less than 5 °C). It should be noted that superhard materials (e.g., PCD, silicon carbide, or PcBN) may include manufacturing size limitations. Therefore, the volume and size of the nozzle 1300 may be limited by the manufacturing size limitations of the superhard materials. Thus, in some embodiments, the nozzle 1300 may be formed by brazing, metallurgically bonding, or otherwise attaching a plurality of superhard bodies (e.g., PCD and / or PcBN bodies) together to form the nozzle 1300, thereby allowing the nozzle 1300 to exhibit at least one of a volume or size greater than the manufacturing limitations of certain superhard materials.

[0100] As described above, any of the nozzles disclosed herein may be formed of PCD. Figure 14 is a schematic diagram of an embodiment of a method for manufacturing nozzle 1400 by PCD according to an embodiment. It should be noted that nozzle 1400 may be any of the nozzles disclosed herein. Referring to Figure 14 , a large number of diamond particles 1460 are provided. The diamond particles 1460 may exhibit an average particle size of about 50 μm or less, such as about 40 μm or less, about 30 μm or less, about 20 μm or less, about 10 μm to about 18 μm, or about 15 μm to about 18 μm. In some embodiments, the average particle size of the diamond particles 1460 may be about 10 μm or less, such as about 2 μm to about 5 μm or sub-micron. The average particle size of the diamond particles 1460 may be selected to minimize the volume loss of the nozzle formed thereby. For example, it has been found that the printing material flowing through the nozzle of the pipe may cause some diamond particles to fall off, resulting in volume loss (i.e., wear) of the nozzle. To minimize the volume loss, the diamond particles 1460 may be selected to exhibit an average particle size of less than 40 μm, such that the effect of the loss of one or several diamond particles on the volume of the nozzle is negligible. However, it should be noted that reducing the average particle size of the diamond particles 1460 may further limit the volume loss, and thus, the diamond particles 1460 may be selected to exhibit an average particle size significantly less than 40 μm, such as less than 20 μm or less than 10 μm.

[0101] In an embodiment, the diamond particles 1460 can include a relatively large dimension and at least one relatively small dimension. As used herein, the terms "relatively large" and "relatively small" refer to particle dimensions that differ by at least a factor of two (e.g., 30 μm and 15 μm) by any suitable method. According to various embodiments, the plurality of diamond particles 1460 can include a portion presenting a relatively large dimension (e.g., 30 μm, 20 μm, 15 μm, 12 μm, 10 μm, 8 μm) and another portion presenting at least one relatively small dimension (e.g., 6 μm, 5 μm, 4 μm, 3 μm, 2 μm, 1 μm, 0.5 μm, less than 0.5 μm, 0.1 μm, less than 0.1 μm). In one embodiment, the plurality of diamond particles 1460 can include a portion presenting a relatively large dimension between about 10 μm and about 40 μm and another portion presenting a relatively small dimension between about 1 μm and 4 μm. In some embodiments, the plurality of diamond particles 1460 can include three or more different dimensions (e.g., one relatively large dimension and two or more relatively small dimensions), but is not limited thereto. It should be noted that due to various different physical processes, such as grain growth, diamond particle fracture, carbon provided by another carbon source (e.g., dissolved carbon in a metal solvent catalyst), or a combination of the foregoing, the sintered diamond particle size may be different from the average particle size of the plurality of diamond particles before sintering.

[0102] The plurality of diamond particles 1460 are positioned adjacent to the bonding surface 1462 of the substrate 1464 to form an assembly 1466. The substrate 1464 can include, but is not limited to, cemented carbides, such as tungsten carbide, titanium carbide, chromium carbide, niobium carbide, tantalum carbide, vanadium carbide, or combinations thereof sintered with iron, nickel, cobalt, or alloys thereof. For example, in one embodiment, the substrate 1464 includes tungsten carbide sintered with cobalt. The substrate 1464 can be generally cylindrical or another 1462 configuration, but is not limited thereto. Although Figure 14 the bonding surface 1462 of the substrate 1464 is shown to be substantially planar, the bonding surface 1462 can present a selected non-planar topography, such as grooved, ridged, or other non-planar bonding surfaces.

[0103] The assembly 1466 also includes a catalyst that is configured to sinter the substantial amount of diamond particles 1460. The catalyst can be provided in particulate form mixed with the substantial amount of diamond particles 1460, as a thin foil or plate disposed adjacent to the substantial amount of diamond particles 1460, or provided by the matrix 1464 (e.g., the matrix 1464 is a sintered carbide matrix including a metal solvent catalyst), or provided by a combination of the two foregoing manners. In an embodiment, the catalyst includes a metal solvent catalyst (e.g., iron, nickel, cobalt, or an alloy thereof). In an embodiment, the catalyst includes at least one non-metal catalyst selected from alkali metal carbonates (e.g., carbonates of one or more of Li, Na, and K), one or more alkaline earth metal carbonates (e.g., carbonates of one or more of Be, Mg, Ca, Sr, and Ba), sulfates (e.g., sulfates of one or more of Be, Mg, Ca, Sr, and Ba), hydroxides (e.g., hydroxides of one or more of Be, Mg, Ca, Sr, and Ba), elemental phosphorus and / or its derivatives, chlorides (e.g., chlorides of one or more of Li, Na, and K), elemental sulfur and / or its derivatives, polycyclic aromatic hydrocarbons (e.g., naphthalene, anthracene, pentacene, perylene, coronene, or a combination of the foregoing), and / or its derivatives, chlorinated hydrocarbons and / or its derivatives, semiconductor materials (e.g., germanium or a germanium alloy), and combinations of the foregoing. In an example, the catalyst includes one or more metal solvent catalysts and one or more non-metal catalysts.

[0104] To effectively sinter the substantial amount of diamond particles 1460, the assembly 1466 can be enclosed in a pressure transfer medium, such as a refractory metal can, a graphite structure, pyrophyllite, and / or other pressure transfer structures suitable for forming a unit assembly. Examples of suitable liner materials and unit structures for use in manufacturing PCD are disclosed in U.S. Patent No. 6,338,754 and U.S. Patent No. 8,236,074, each of which is hereby incorporated by reference in its entirety. Another example of a suitable pressure transfer material is pyrophyllite, which can be obtained from Wonderstone Ltd. of South Africa.

[0105] A unit assembly 1466 including a pressure transfer medium and the substantial amount of diamond particles 1460 undergoes an HPHT process using an ultra-high pressure press at a temperature of at least about 1000 °C (e.g., from about 1100 °C to about 2200 °C, or from about 1200 °C to about 1450 °C) and at a pressure of at least about 5 GPa (e.g., from about 7.5 GPa to about 15 GPa, at least about 8.0 GPa, at least about 9.0 GPa, at least about 10.0 GPa, at least about 11.0 GPa, at least about 12.0 GPa, or at least about 14 GPa) for a sufficient time to sinter the diamond particles 1460 together in the presence of a catalyst and form a PCD table 1468 that includes bonded diamond particles defining an interstitial region occupied by the catalyst. The HPHT process can form a PCD compact 1470 that includes the PCD table 1468 bonded to a substrate during the HPHT process, the catalyst can liquefy, and if the catalyst is disposed external to the diamond particles 1460, the catalyst can infiltrate the substantial amount of diamond particles 1460. The catalyst promotes growth between adjacent diamond particles among the substantial amount of diamond particles 1460 to form a PCD table 1468 that includes a body of bonded diamond particles having infiltrated catalyst disposed in an interstitial manner between the bonded diamond particles. For example, if the substrate 1464 is a sintered cobalt tungsten carbide substrate, cobalt from the substrate 1464 can liquefy and infiltrate the substantial amount of diamond particles 1460 to catalyze the formation of the PCD table 1468.

[0106] The pressure value used in the HPHT process disclosed herein refers to the pressure in the pressure transfer medium when pressure is applied using a ultra-high pressure press at room temperature (e.g., about 25 °C), rather than the pressure applied to the outside of the unit assembly 1466. The actual pressure in the pressure transfer medium at the sintering temperature may be slightly higher. The ultra-high pressure press can be calibrated at room temperature by embedding at least one calibration material (such as lead telluride, thallium, barium, or bismuth) that changes structure at a known pressure into the pressure transfer medium. Additionally, optionally, the change in resistance due to its phase change on the at least one calibration material can be measured. For example, lead telluride exhibits a phase change at room temperature at about 6.0 GPa, while bismuth exhibits a phase change at room temperature at about 7.7 GPa. Examples of suitable pressure calibration techniques are disclosed in G. Rousse, S. Klotz, A. M. Saitta, J. Rodriguez-Carvajal, M. I. McMahon, B. Couzinet, and M. Mezouar, "Structure of the Intermediate Phase of PbTe at High Pressure", Physical Review B: Condensed Matter and Materials Physics, 71, 224116 (2005) and D. L. Decker, W. A. Bassett, L. Merrill, H. T. Hall, and J. D. Barnett, "High-Pressure Calibration: A Critical Review", J. Phys. Chem. Ref. Data, 1, 3 (1972).

[0107] In other embodiments, the PCD platelet 1468 according to the embodiment can be formed separately using the HPHT sintering process and then bonded to the bonding surface 1462 of the substrate 1464 by brazing, using a separate HPHT bonding process, or any other suitable joining technique (without limitation). In yet another embodiment, the substrate 1464 can be formed by depositing binderless carbide (e.g., tungsten carbide) onto the separately formed PCD platelet 1468 via chemical vapor deposition.

[0108] In any of the embodiments disclosed herein, substantially all or a selected portion of a catalyst (e.g., a metal solvent catalyst) can be removed from the PCD platelet 1468 (e.g., via leaching). In an embodiment, the metal solvent catalyst in the PCD platelet 1468 can be removed from at least one external working surface (e.g., the working surface and / or the sidewall working surface of the PCD platelet 1468) to a selected depth such that only a portion of the interstitial region is occupied by the metal solvent catalyst. For example, substantially all or a selected portion of the metal solvent catalyst can be removed from the thus-formed PCD platelet 1468 in the PCD blank 1470 to a selected depth. Leaching the catalyst from the PCD platelet 1468 can improve the thermal stability of the nozzle 1400 formed from the PCD platelet 1468. For example, leaching the catalyst from the PCD platelet 1468 can allow the PCD platelet to be brazed to the base and / or heated to a temperature of about 700 °C or greater without substantial thermal degradation. In some embodiments, the catalyst may not be leached from the PCD platelet 1468. In some embodiments, the catalyst may be leached only from a portion of the PCD platelet to improve the thermal stability of the nozzle 1400 formed from the PCD platelet.

[0109] In another embodiment, the PCD platelet 1468 can be fabricated in a first HPHT process according to any of the disclosed embodiments, leached to remove substantially all of the metal solvent catalyst from the interstitial regions between the bonded diamond grains, and subsequently bonded to a substrate in a second HPHT process. In the second HPHT process, an infiltrant, e.g., from a cobalt sintered carbide substrate, can penetrate into the metal solvent catalyst-depleted interstitial regions. For example, the infiltrant can be cobalt swept in from a cobalt sintered tungsten carbide substrate. In one embodiment, the first HPHT process and / or the second HPHT process can be carried out at a pressure of at least about 7.5 GPa. In one embodiment, a second acid leaching process can be used to leach the infiltrant from the infiltrated PCD platelet 1468 after the second HPHT process.

[0110] In an embodiment, the PCD platelet 1468 can be a binderless PCD platelet. The binderless PCD platelet can be formed by pressing a large number of diamond grains (with or without additives such as catalysts). The diamond grains are pressed without any metal solvent catalyst. For example, the large number of diamond grains may not be disposed on a cobalt sintered tungsten carbide substrate. Any of the pressures and temperatures disclosed herein can be used to press the binderless PCD platelet.

[0111] In an embodiment, as shown, the substrate 1464 can be removed from or otherwise separated from the PCD platelet 1468. For example, the substrate 1464 can be removed from the PCD platelet 1468 by grinding the substrate 1464 or dissolving the substrate 1464 in an acid. In an embodiment not shown, at least a portion of the substrate 1464 may not be removed from or otherwise separated from the PCD platelet 1468. In such an embodiment, the substrate 1464 can form part of one or more nozzles formed by the PCD platelet 1468.

[0112] The PCD platelet 1468 and optionally a portion of the substrate 1464 can be removed to form one or more nozzles 1400. For example, the PCD platelet 1468 and optionally a portion of the substrate 1464 can be removed (e.g., via laser ablation) to form 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, or greater than 20 nozzles 1400. The number of nozzles 1400 formed from the PCD platelet 1468 and optionally the substrate 1464 can depend on the size of the PCD platelet 1468 (e.g., maximum lateral dimension, thickness, and volume), the shape of the PCD platelet 1468, whether the substrate 1464 forms part of the nozzle 1400, the size of the nozzle 1400, and the shape of the nozzle 1400. It should be noted that the nozzles 1400 formed from the PCD platelet 1468 and the optional substrate 1464 can include one or more features that are the same as or substantially similar to any of the one or more features of the nozzles disclosed herein, without limitation.

[0113] In an embodiment, a laser can be used to remove a portion of the PCD platelet 1468 and optionally a portion of the substrate 1464. In such an embodiment, the laser can emit a plurality of laser pulses towards one or more surfaces of the PCD platelet 1468 and optionally the substrate 1464. The laser pulses can be selected to remove the PCD platelet 1468 in a manner of one or more layers. The laser ablation process can achieve at least one of the following: forming a plurality of nozzles 1400 from the PCD platelet 1468 (e.g., simultaneously or substantially simultaneously); forming external features (e.g., top surface, bottom surface, side surface, etc.) of the nozzles 1400; forming internal features (e.g., ducts) of the nozzles 1400; or polishing the surfaces of the nozzles 1400. Examples of laser methods that can be used to remove a portion of the PCD platelet 1468 are disclosed in U.S. Patent Application No. 16 / 084,469, filed on January 10, 2018, the disclosure of which is incorporated herein by reference in its entirety.

[0114] In an embodiment, one or more of grinding, lapping, electrical discharge machining (e.g., wire electrical discharge machining), or any other machining technique can be used to remove a portion of the PCD platelet 1468 and optionally a portion of the substrate 1464. Different from laser machining, some machining techniques such as grinding, lapping, and electrical discharge machining may exhibit at least one of the following: presenting high wear due to the hardness of diamond; may not be able to form all the nozzles 1400 together (e.g., in a single process); may not be able to form external and internal features of the nozzles 1400; or may not be able to polish the surfaces of the nozzles 1400. In an embodiment, laser machining and one or more of grinding, lapping, electrical discharge machining, or any other machining technique can be used to remove a portion of the PCD platelet 1468 and optionally a portion of the substrate 1464.

[0115] As described above, the nozzles disclosed herein can be formed at least in part of PcBN, rather than formed of PCD or formed of PcBN in addition to PCD. More generally, the nozzles disclosed herein can include one or more superhard materials (e.g., PCD, PCBN, silicon carbide, or any material having a hardness exceeding the hardness of tungsten carbide), but are not limited thereto. For example, since the hardness and thermal conductivity of PcBN are comparable to the hardness and thermal conductivity of PCD, the nozzles can be formed at least in part of PcBN. Nozzles formed of PcBN can reduce nozzle wear, can increase the service life of the nozzles, can allow the nozzles to be used with abrasive printing materials, and can improve the consistency of the printing materials formed using the nozzles. PcBN can exhibit a higher thermal stability than PCD, thereby allowing the nozzles formed of PcBN to be heated to higher temperatures compared to when the nozzles include PCD. For example, when PCD contains a metal solvent catalyst, PCD may exhibit thermal degradation when heated to temperatures above 700 °C, while PcBN can be heated to temperatures above 700 °C with substantially no degradation.

[0116] In an embodiment, the entire nozzle can be formed of PcBN. Forming the entire nozzle of PcBN can make the manufacture of the nozzle easier because there is no need to attach PcBN to another material and can improve the wear characteristics of the nozzle. In another embodiment, only a portion of the nozzle is formed of PcBN. Forming only a portion of the nozzle of PcBN can make the shaping and machining of the nozzle easier because the other materials of the nozzle may have a lower hardness than PcBN. However, forming only a portion of the nozzle of PcBN may require bonding PcBN to another material, thereby increasing the complexity of manufacturing the nozzle. In addition, the fact that a portion of the nozzle is formed of a material having a lower hardness than PcBN may increase the wear of the portion of the nozzle formed of the lower hardness material, thereby reducing the service life of the nozzle. In an example, when only a portion of the nozzle includes PcBN, at least a portion of the conduit surface 110, and more specifically, the portion of the conduit surface 110 adjacent to the orifice 114 and any other inner surface of the nozzle adjacent to the orifice 114, can be defined by PcBN. In such an example, PcBN reduces the wear of the orifice 114 compared to the lower hardness material, thereby maintaining the consistency of the printing material dispensed from the nozzle compared to when the nozzle is formed entirely of the lower hardness material.

[0117] PcBN can be formed by heating boron nitride at any one of the same temperatures and pressures as described above, such as a temperature of about 1000 °C to about 1450 °C and a pressure of about 5 GPa to about 14 GPa. Catalysts for PcBN include, for example, alkali metals, antimony, lead, tin, lithium, magnesium, and nitrides. After forming PcBN, one or more nozzles can be formed from PcBN using the same techniques as those disclosed above for PCD. For example, the nozzles can be formed by laser machining, grinding, lapping, electrical discharge machining, or any other suitable machining technique.

[0118] In some embodiments, one or more nozzles can be produced via a process of forming a nozzle having a selected orifice geometry. For example, the nozzle can have an exit orifice that exhibits a selected ratio between a height extending along a fluid flow direction (e.g., a fluid path through the nozzle) and a width (e.g., diameter) extending along a direction transverse to (e.g., substantially perpendicular to) the height and / or the fluid path. The processes discussed herein can achieve a selected height / diameter ratio of the orifice located at the nozzle exit. For example, such a method of processing a material (e.g., a superhard material such as PCD) can achieve the production of nozzles having an orifice geometry with a height / diameter ratio of 1.2 or less (e.g., less than 1, less than 0.75, less than 0.5, less than 0.32, less than 0.25, less than 0.2, between 0.1 and 1.2, between 0.1 and 0.5, between 0.1 and 0.4, between 0.1 and 0.3, between 0.1 and 0.2, etc.). In some embodiments, such an orifice geometry can achieve a reduction in backpressure in the nozzle and can achieve an increase in the printing speed implemented by the nozzle in a printing application.

[0119] Figure 15 and Figure 16 shows an interior portion of nozzle 1500 that is defined within a volume or block of material (e.g., PCD plate 1504 or disk) via one or more machining processes (e.g., by laser ablation). Although for clarity, Figure 15 nozzle 1500 in is shown as already having some external features formed in PCD plate 1504, it should be understood that PCD plate 1504 can be a volume of material having only some of the features of one or more internal features formed therein.

[0120] As described above, in some embodiments, nozzle 1500 can be formed from a superhard material (e.g., PCD) along with a plurality of other nozzles. As described above, in some embodiments, when nozzle 1500 is an entire PCD plate (e.g., Figure 14When forming a portion of the PCD plate member 1468) as shown, the internal portion of the nozzle 1500 (e.g., the conduit 1502) can be defined. The external portion of the nozzle 1500 (e.g., the exterior 1520) can be formed when each nozzle 1500 is separated from the PCD plate member (e.g., separated from the entire PCD plate member). In additional embodiments, the nozzle 1500 can be formed separately, and / or the external portion is defined during one or more machining processes before defining one or more portions of the conduit 1502.

[0121] As Figure 15 As shown, the PCD plate member 1504 can be loaded into a fixture 1506 (e.g., a machining fixture), and the fixture 1506 uses clamping force to hold the position of the PCD plate member 1504. The fixture 1506 can position the PCD plate member 1504 such that the bottom or proximal side 1510 is exposed, so that material can be removed from the proximal side 1510. The first portion 1508 of the conduit 1502 (e.g., the proximal portion or inlet portion formed as a blind hole having a generally tapered shape) can be machined (e.g., laser machined) into the PCD plate member 1504. Other geometries on or near the bottom or proximal side 1510 of the nozzle 1500 can be formed during the same machining process of the proximal side 1510 of the nozzle 1500.

[0122] As Figure 16 As shown, the fixture 1506 can then be rotated (e.g., rotated 180 degrees, flipped, etc.) and reinstalled or repositioned on the machining apparatus (e.g., exposing the distal side 1511 of the nozzle 1500 for machining). In some embodiments, a support material member and / or a bottom plate 1512 can be placed on the first portion 1508 of the conduit 1502 to support the PCD plate member 1504 during subsequent processing.

[0123] The second portion 1514 of the conduit 1502 can be machined (e.g., laser machined) into the nozzle 1500. For example, the second portion 1514 can define an orifice 1515, and the orifice 1515 includes the distal portion or outlet portion of the conduit 1502. The second portion 1514 can be formed to connect with the first portion 1508 to form the entire through - hole of the conduit 1502, thereby providing a fluid outlet at the orifice 1515. The through - hole of the conduit 1502 can define a fluid path 1518 through the nozzle 1500, and the fluid path 1518 can extend substantially along the axial direction of the nozzle 1500.

[0124] As described below, the outlet orifice 1515 may be a substantially straight orifice (e.g., having a substantially constant diameter) or may be tapered. For example, the second portion 1514 or the orifice 1515 may have a generally conical shape that is opposite to the conical shape of the first portion 1508, wherein the diameter of the orifice 1515 may increase as the orifice 1515 approaches the distal side 1511 of the nozzle 1500. In such an embodiment where the orifice 1515 is tapered, the inner surface of the nozzle 1500 that forms the orifice 1515 may include a taper of 1 degree to 45 degrees, 5 degrees to 15 degrees, less than 30 degrees, 0.1 degree to 30 degrees, etc. (e.g., an angle relative to the central axis of the nozzle 1500).

[0125] In some embodiments, as shown, the junction between the orifice 1515 and the first portion 1508 may include a diameter-reduced portion to define a neck portion of the nozzle 1500.

[0126] In some embodiments, the most distal portion of the orifice 1515 may include a chamfered or rounded portion 1516 located at the most distal portion of the conduit 1502. For example, all or a portion (e.g., the most distal portion) of the orifice 1515 may include the chamfered portion 1516.

[0127] In some embodiments, during the same setup (e.g., Figure 16 the same orientation of the fixture 1506 as shown), the exterior 1520 of the nozzle 1500 (e.g., the outer taper of the tip end portion of the nozzle 1500) may be defined and the nozzle 1500 may be separated from the entire PCD plate-like member 1504. This configuration enables the second portion 1514 and the orifice 1515 to be formed together with the action of separating the nozzle 1500 from the PCD plate-like member 1504, and any other nozzles 1500 are formed substantially simultaneously (e.g., via the same sequence of actions as the initial nozzle 1500).

[0128] In some embodiments, such a manufacturing method (wherein the conduit 1502 is formed in at least two separate actions) may help maintain the concentricity of the outlet orifice 1515 (e.g., the second portion 1514) with one or more portions of the diameter of the nozzle 1500 (e.g., the outer diameter portion of the tip end portion of the nozzle 1500 and / or the outer taper of the exterior 1520 of the nozzle 1500).

[0129] Figures 17 to 19 Examples of nozzles 1700, 1800, 1900 are shown, which may be formed by a process including machining steps performed on multiple sides of a material piece. For example, the nozzles 1700, 1800, 1900 may be formed by a process such as that described above with reference to Figure 15 and Figure 16formed during the process of discussion and so on. As Figures 17 to 19 shown, the nozzles 1700, 1800, 1900 can each present orifices 1714, 1814, 1914 at the outlets of the nozzles 1700, 1800, 1900, and the orifices 1714, 1814, 1914 have a height (e.g., along the longitudinal axis, centerline, or fluid flow path through the nozzles 1700, 1800, 1900) that is relatively small compared to the width (e.g., the diameter obtained in a direction transverse to the height).

[0130] In some embodiments, the conduits 1702, 1802, 1902 of the nozzles 1700, 1800, 1900 can present a generally conical shape and can include one or more inner surface portions positioned at an angle relative to each other, as discussed in detail above.

[0131] As Figure 17 shown, the nozzle 1700 can include an orifice 1714 having a height / diameter ratio less than 1.2 (e.g., less than 0.4, about 0.31). For example, the orifice 1714 can have a height of about 0.005 inches and a diameter of 0.016 inches. In some embodiments, the orifice 1714 can be tapered (e.g., a taper of about 12 degrees) and can include a chamfered portion 1716.

[0132] As Figure 18 shown, the nozzle 1800 can include an orifice 1814 having a height / diameter ratio less than 1.2 (e.g., less than 0.25, about 0.2). For example, the conduit 1802 can have a height of about 0.005 inches and a diameter of 0.024 inches. In some embodiments, the orifice 1814 can be tapered (e.g., a taper of about 5 degrees) and can include a chamfered portion 1816.

[0133] As Figure 19 shown, the nozzle 1900 can include an orifice 1914 having a height / diameter ratio less than 1.2 (e.g., less than 0.20, about 0.16). For example, the conduit 1902 can have a height of about 0.005 inches and a diameter of 0.031 inches. In some embodiments, the orifice 1914 can be formed as a straight-wall orifice and can include a chamfered portion 1916.

[0134] Although various aspects and embodiments have been disclosed herein, other aspects and embodiments are also contemplated. The various aspects and embodiments disclosed herein are for illustrative purposes only and are not intended to be limiting.

[0135] Degree terms (e.g., "about", "substantially", "generally", "approximately", etc.) denote changes that are not obvious in structure or function. In an example, when a degree term includes a term representing a quantity, the degree term is interpreted to mean ±10%, ±5%, +2%, +1%, or even +0% of the term representing the quantity. In an example, when a degree term is used to modify a shape, the degree term indicates that the shape modified by the degree term has the appearance of the disclosed shape. For example, the degree term may be used to indicate that the shape may have rounded corners instead of sharp corners, the shape has curved edges instead of straight edges, the shape has one or more protrusions extending therefrom, the shape is elongated, and the shape is the same as the disclosed shape.

Claims

1. A method of forming a nozzle for use in a three-dimensional printing process, the method comprising: Fixing a piece of material in a processing fixture; Forming a hole in the piece of material on a first side portion thereof to define an at least partially tapered inner duct that at least partially extends through the piece of material; Forming a through hole in the piece of material on a second side portion thereof to define an outlet orifice of the nozzle, the outlet orifice being connected to the at least partially tapered inner duct to define a fluid path through the nozzle; Defining the outlet orifice to have a height extending in a direction along the fluid path of the nozzle and a width extending in a direction transverse to the height of the outlet orifice, the ratio of the height to the width being substantially 1.2 or less; And Forming an exterior of the nozzle to remove the nozzle from the remainder of the piece of material.

2. The method according to claim 1, wherein the method further comprises: After forming the hole in the first side portion of the piece of material, rotating the piece of material 180 degrees to expose the second side portion.

3. The method according to claim 2, the method further comprising: Defining the outlet orifice such that the ratio of the height to the width is less than 0.

5.

4. The method according to claim 3, the method further comprising: Defining the outlet orifice such that the ratio of the height to the width is less than 0.

35.

5. The method according to claim 1, the method further comprising: Defining a chamfer portion at a most distal portion of the outlet orifice.

6. The method according to claim 1, wherein the method further comprises: Forming the orifice to present a tapered inner surface having a taper of 0.1 degrees to 30 degrees.

7. The method according to any one of claims 1 to 6, the method further comprising: Forming a plurality of nozzles from at least a portion of the remainder of the piece of material substantially simultaneously with the nozzle.

8. The method according to any one of claims 1 to 6, wherein, Fixing the piece of material in the processing fixture includes: fixing a polycrystalline diamond plate-like piece in the processing fixture.

9. The method according to any one of claims 1 to 6, wherein Forming the hole in the piece of material includes: forming a blind hole in the piece of material.

10. A method of forming a nozzle for use in a three-dimensional printing process, the method comprising: On a first side portion of a piece of material, forming a hole in the piece of material to define an at least partially tapered inner duct that at least partially extends through the piece of material; Redirecting the piece of material to expose a second side portion opposite the first side portion; On the second side portion of the material, forming a through hole in the piece of material to define an outlet orifice of the nozzle, the outlet orifice being connected to the at least partially tapered inner duct to define a fluid path through the nozzle; And Removing the nozzle from the remainder of the piece of material.

11. The method according to claim 10, wherein the method further comprises: Shaping the outlet orifice to have a height extending in a direction along the fluid path of the nozzle and a width extending in a direction transverse to the height of the outlet orifice, the ratio of the height to the width being substantially 1.2 or less.

12. The method according to claim 10, the method further comprising: While forming the exterior of the nozzle, continue to expose the second side portion of the piece of material.

13. The method according to any one of claims 10 to 12, the method further comprising: Forming additional nozzles from the piece of material substantially simultaneously with the nozzle.

14. The method according to any one of claims 10 to 12, the method further comprising: Forming a hole that only partially penetrates the piece of material to define a blind hole.

15. A nozzle for three-dimensional printing, the nozzle comprising: At least one proximal surface that defines an inlet of the nozzle; At least one distal surface, opposite to the at least one proximal surface, that defines an outlet of the nozzle; At least one outer surface that extends from the at least one proximal surface to the at least one distal surface; And At least one duct surface that extends from the at least one proximal surface to the at least one distal surface, the at least one duct surface defining a fluid flow duct through the nozzle; wherein a junction between the at least one duct surface and the at least one distal surface defines an outlet orifice of the nozzle; and wherein the outlet orifice presents a height extending in a direction along the fluid flow duct and a width extending in a direction transverse to the height of the outlet orifice, and a ratio of the height to the width is substantially 1.2 or less.

16. The nozzle according to claim 15, wherein, The ratio of the height to the width is substantially 0.75 or less.

17. The nozzle according to claim 16, wherein, The ratio of the height to the width is substantially 0.5 or less.

18. The nozzle according to claim 17, wherein, The ratio of the height to the width is substantially 0.35 or less.

19. The nozzle according to any one of claims 15 to 18, further comprising a chamfer portion located at a most distal portion of the outlet orifice.

20. The nozzle according to any one of claims 15 to 18, wherein, The orifice presents a tapered inner surface having a taper of 0.1 degree to 30 degrees.

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