Nozzles, nozzle assemblies, and related methods

Abstract

Examples are directed to nozzles for three-dimensional printing, and related assemblies and methods. An example method includes forming a hole in the material on a first side thereof to define an at least partially conical inner conduit extending at least partially through the material, and forming a through-hole in the material on a second side thereof to define an exit orifice of the nozzle, the exit orifice connecting with the at least partially conical inner conduit to define a fluid pathway through the nozzle.

Description

[Background technology]

[0001] Three-dimensional ("3D") printing is a method that involves dispensing a first layer of material from a nozzle onto a platform. Additional layers of material can be dispensed from the nozzle onto the first and subsequent layers until an object is formed. However, conventional nozzles and conventional nozzle assemblies having such nozzles present several problems, such as inadequate leakage of dispensed material and excessive nozzle wear.

[0002] Therefore, there is a need for new and improved nozzles and nozzle assemblies containing such nozzles. [Prior art documents] [Non-patent literature]

[0003] [Non-Patent Document 1] G. Rousse, S. Klotz, AMSaitta, J. Rodriguez-Carvajal, MIMcMahon, B. Couzine, and M. Mezouar, "Structure of the Intermediate Phase of PbTe at High Pressure", Physical Review B: Condensed Matter and Materials Physics, 71, 224116 (2005) [Non-patent document 2] DLDecker, WA Bassett, L. Merrill, HTHall, and JD Barnett, "High-Pressure Calibration: A Critical Review," J.Phys.Chem.Ref.Data, 1, 3 (1972) Summary of the Invention [Means for solving the problem]

[0004] Embodiments are directed to nozzles and associated nozzle assemblies for three-dimensional printing, as well as methods of forming and using the nozzles. In the embodiments, a nozzle for three-dimensional printing is disclosed. The nozzle can have 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 conduit surface extending from the at least one top surface to the at least one bottom surface. The at least one conduit surface defines a conduit. In some embodiments, at least a portion of the at least one conduit surface near the at least one top surface is non-vertical. At least a portion of the at least one conduit surface comprises at least one superhard material.

[0005] In some embodiments, a nozzle assembly for three-dimensional printing is disclosed. The nozzle assembly includes a base having a mounting portion configured to be attached to a printing device, and a nozzle attached to the base. The nozzle can have 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 conduit surface extending from the at least one top surface to the at least one bottom surface. The at least one conduit surface defines a conduit. In some embodiments, at least a portion of the at least one conduit surface near the at least one top surface is non-vertical. At least a portion of the at least one conduit surface includes at least one superhard material.

[0006] Some embodiments may include methods of forming and / or using nozzles and nozzle assemblies.

[0007] For example, a method of forming a nozzle may include defining at least one conduit surface extending through the nozzle, extending at least a portion of the at least one conduit surface transversely to a central axis of the nozzle, and forming at least a portion of the at least one conduit surface using at least one superhard material.

[0008] In some examples, a method of using a nozzle in a three dimensional printing process can include flowing a fluid (e.g., a printing material) through a conduit of the nozzle defined by a conduit surface comprising at least one superhard material, and directing the fluid flow through the conduit comprising at least a portion of the conduit surface in a direction transverse to a central axis of the nozzle.

[0009] In some aspects, techniques described herein relate to a method of forming a nozzle for use in a three dimensional printing process, the method including: fixing a material in a machining fixture; forming a hole in the material on a first side of the material to define an at least partially conical inner conduit extending at least partially through the material; forming a through hole in the material on a second side of the material to define an exit orifice of the nozzle, the exit orifice connecting with the at least partially conical inner conduit to define a fluid path through the nozzle; defining the exit orifice to have a height extending in a direction along the fluid path of the nozzle and a width extending 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 portion of the nozzle to detach the nozzle from a remainder of the material.

[0010] In some aspects, techniques described herein relate to a method of forming a nozzle for use in a three dimensional printing process, the method including: forming a hole in the material at a first side of the material to define an at least partially conical inner conduit extending at least partially through the material; reorienting the material to expose a second side opposite the first side; forming a through hole in the material at the second side of the material to define an exit orifice of the nozzle, the exit orifice connecting with the at least partially conical inner conduit to define a fluid pathway through the nozzle; and forming an exterior portion of the nozzle to detach the nozzle from a remainder of the material.

[0011] In some aspects, techniques described herein relate to a nozzle for three-dimensional printing, the nozzle including: at least one proximal surface defining an inlet of the nozzle; at least one distal surface opposite the at least one proximal surface, the distal surface defining an outlet of the nozzle; at least one outer surface extending from the at least one proximal surface to the at least one distal surface; and at least one conduit surface extending from the at least one proximal surface to the at least one distal surface, the at least one conduit surface defining a fluid flow conduit through the nozzle, wherein the interface between the at least one conduit surface and the at least one distal surface defines an outlet orifice of the nozzle, the outlet orifice exhibiting a height extending in a direction along the fluid flow conduit 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.

[0012] Features from any of the disclosed embodiments may be used in combination with each other, including but not limited to. Additionally, other features and advantages of the present disclosure will become apparent to those skilled in the art from a consideration of the following detailed description and accompanying drawings.

[0013] The drawings illustrate several embodiments of the present disclosure, where like reference numerals indicate like or similar elements or features in different figures or in different embodiments shown in the drawings. [Brief explanation of the drawings]

[0014] [Figure 1A] FIG. 1 is an isometric view of a nozzle, according to an embodiment. [Figure 1B] 1B is a schematic cross-sectional view of a nozzle taken along plane 1B-1B shown in FIG. 1A, according to an embodiment. [Figure 1C] FIG. 1C is an enlarged view of a portion of the nozzle within circle 1C shown in FIG. 1B, according to an embodiment. [Figure 1D] 1C is an enlarged view of a portion of the nozzle within circle 1C shown in FIG. 1B according to a different embodiment than that shown in FIG. 1C. [Figure 2] 1 is a schematic cross-sectional view of a nozzle according to an embodiment; [Figure 3] 10A-10C are schematic cross-sectional views illustrating different nozzles having curved conduit surfaces according to different embodiments. [Figure 4] 10A-10C are schematic cross-sectional views illustrating different nozzles having curved conduit surfaces according to different embodiments. [Figure 5] 10A-10C are top views illustrating nozzles each having orifices with a non-circular cross-sectional shape according to different embodiments. [Figure 6] 10A-10C are top views illustrating nozzles each having orifices with a non-circular cross-sectional shape according to different embodiments. [Figure 7] 10A-10C are schematic cross-sectional views of different nozzles, each having a chamfer extending from its top surface to its side or conduit surface, according to different embodiments. [Figure 8] 10A-10C are schematic cross-sectional views of different nozzles, each having a chamfer extending from its top surface to its side or conduit surface, according to different embodiments. [Figure 9A] 1 is a schematic cross-sectional view illustrating a nozzle configured to increase the surface area of ​​printed material formed by the nozzle, according to an embodiment. [Figure 9B]9B is an enlarged schematic cross-sectional view of a portion of a nozzle having a recess within circle 9B shown in FIG. 9A, according to an embodiment. [Figure 9C] 10A-10C are enlarged schematic cross-sectional views showing portions of a nozzle having recesses according to different embodiments. [Figure 9D] 10A-10C are enlarged schematic cross-sectional views showing portions of a nozzle having recesses according to different embodiments. [Figure 10] 1 is a schematic cross-sectional view illustrating a nozzle configured to increase the surface area of ​​printed material formed by the nozzle, according to an embodiment. [Figure 11] 1 is a schematic cross-sectional view of a nozzle assembly having a nozzle attached to a base, according to an embodiment. [Figure 12] 1 is a schematic cross-sectional view illustrating a nozzle assembly having a nozzle attached to a base, where the maximum lateral dimension is equal to or greater than the maximum lateral dimension of the base, according to an embodiment. [Figure 13] 1 is a schematic cross-sectional view of a nozzle assembly having a nozzle and no base, according to an embodiment; [Figure 14] 1 is a schematic diagram illustrating an example of a method for making a nozzle from polycrystalline diamond, according to an example embodiment; [Figure 15] FIG. 1 illustrates an interior portion of a nozzle defined within a block of material, according to an embodiment of the present disclosure. [Figure 16] FIG. 1 illustrates an interior portion of a nozzle defined within a block of material, according to an embodiment of the present disclosure. [Figure 17] 1A-1C illustrate examples of nozzles formed by a process according to embodiments of the present disclosure. [Figure 18] 1A-1C illustrate examples of nozzles formed by a process according to embodiments of the present disclosure. [Figure 19] 1A-1C illustrate examples of nozzles formed by a process according to embodiments of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0015] The present disclosure relates to nozzles and associated nozzle assemblies for three-dimensional printing, as well as methods of forming and using nozzles. Exemplary nozzles have at least one top surface, at least one bottom surface, and at least one side surface extending from or near the top surface to or near the bottom surface. The nozzle further has at least one conduit surface defining a conduit. The conduit surface extends from or near the top surface to or near the bottom surface. In embodiments, at least a portion of the conduit surface closest to the top surface is non-perpendicular (e.g., forms a non-cylindrical or non-rectangular shape and extends along an axis that is transverse to the central axis of the nozzle). In such embodiments, a conduit surface is non-perpendicular if the conduit surface is non-parallel (e.g., transverse) to the central axis of the nozzle extending from the top surface to the bottom surface.

[0016] Nozzle features disclosed herein can be configured to, for example, reduce the force required to extrude a printing material through a conduit, assist in removing a first printing material to prevent contamination of a second, different printing material that may subsequently flow through the conduit, prevent clogging of the conduit, improve heating of the printing material flowing through the nozzle, improve resolution of the printed material, and / or improve adhesion of different layers of the printed material. These features can be useful when flowing any printing material through a conduit, but can be particularly useful when flowing an abrasive printing material through the nozzle. Abrasive printing materials can include printing materials that exhibit hardness comparable to or greater than brass, steel, or other materials commonly used to form nozzles. Examples of abrasive printing materials include polymers, ceramics, metals, composites, or combinations thereof, having one or more particles (e.g., ceramic particles, metal particles, carbon fibers, etc.) disposed therein. It should be noted that as used herein, the term "printed material" refers to the material (e.g., a fluid or another flowable material) that flows through a conduit, and the term "printed material" refers to the material that has been dispensed from a nozzle.

[0017] Features of the nozzles disclosed herein may create structures that are more likely to wear away as abrasive printing materials flow through the conduit, potentially negating the benefits of the structures disclosed herein. Thus, in some examples, the nozzles disclosed herein may include (or be formed at least in part from) at least one of polycrystalline diamond (PCD) or polycrystalline cubic boron nitride (PcBN), another superhard material exhibiting a hardness equal to or greater than that of tungsten carbide, and / or any combination of the above. For example, the nozzles may be formed to allow features of the nozzles disclosed herein to be defined and / or formed from PCD, PcBN, or another superhard material. Furthermore, it should be noted that forming at least a portion of the nozzles disclosed herein from at least one of PCD and / or PcBN can improve the thermal conductivity of the nozzles, thereby improving heating of the printing material compared to nozzles formed from another superhard material.

[0018] As used herein, terms indicating relationships between elements, such as "first," "second," "top," "bottom," etc., are generally used for clarity and convenience in understanding this disclosure and the accompanying drawings, and do not imply or rely on a particular priority, orientation, or order unless clearly indicated by context.

[0019] As used herein, the term "and / or" is intended to mean any and all combinations of one or more of the associated listed items.

[0020] As used herein, the terms "vertical," "upper," "lower," and "lateral" refer to the orientation depicted in the figures.

[0021] FIG. 1A is an isometric view of a nozzle 100, according to an embodiment. FIG. 1B is a schematic cross-sectional view of the nozzle 100 taken along plane 1B-1B shown in FIG. 1A, according to an embodiment. The nozzle 100 has at least one top surface 102, at least one bottom surface 104 opposite the top surface 102, at least one side surface 106, and optionally at least one chamfer (e.g., chamfer 108). In the embodiment shown, the side surface 106 extends from the top surface 102 to a position near the bottom surface 104 (e.g., to the chamfer 108 extending between the bottom surface 104 and the side surface 106). However, the side surface 106 can extend from a position near the top surface 102 if the nozzle 10 has an outer chamfer extending between the top surface 102 and the side surface 106, or can extend to the bottom surface 104 if the chamfer 108 is not present. The nozzle 100 further includes at least one conduit surface 110 that defines a conduit 112. At least a portion of the conduit surface 110 can include at least one ultra-hard material that exhibits a hardness equal to or greater than that of tungsten carbide. Such a configuration can limit wear on the conduit surface 110. In the example shown, the conduit surface 110 extends from the top surface 102 to the bottom surface 104. However, the nozzle 100 can have at least one chamfer that extends from at least one of the top surface 102 or the bottom surface 104 to the conduit surface 110. The top surface 102 and / or the conduit surface 110 define an orifice 114 through which the printing material is dispensed from the nozzle 100, and the bottom surface 104 and / or the conduit surface 110 define an opening 116 through which the conduit 112 can receive the printing material.

[0022] As discussed above, the top surface 102 of the nozzle defines an orifice 114. The orifice 114 may have a diameter of about 0.25 mm, about 0.4 mm, about 0.6 mm, about 0.8 mm, about 1.0 mm, about 0.1 mm or more, about 0.2 mm or more, about 0.4 mm or more, about 0.6 mm or more, about 0.8 mm or more, about 1 mm or more, about 1.5 mm or more, about 2 mm or more, about 3 mm or less, about 2 mm or less, about 1 mm or less, about 0.75 mm or less, about 0.5 mm or less, or about 0.1 mm to about 0.3 mm, The orifice 114 may have a maximum lateral dimension (e.g., diameter) ranging from 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, 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 may affect the achievable resolution of the printed material and the rate at which the printing material can be dispensed by the nozzle 100. For example, increasing the maximum lateral dimension of the nozzle 114 may increase the rate at which the printing material can be dispensed by the nozzle 100, but may decrease the achievable resolution of the printed material.

[0023] The top surface 102 is approximately 0.075 mm 2 More than 0.1mm 2 More than 0.2mm 2 or more, about 0.3mm 2 More than 0.5mm 2 More than 0.7mm 2 More than 1mm 2 or more, about 1.25mm 2 More than 1.5mm 2 More than 2mm 2 or more, about 3mm 2 or more, about 4mm 2 More than or equal to approximately 0.075 mm 2 Approximately 0.2 mm 2 , about 0.1mm 2 Approximately 0.3 mm 2 , about 0.2 mm 2 Approximately 0.4 mm 2 , about 0.3mm2 from about 0.5 mm 2 , about 0.4mm 2 Approximately 0.6 mm 2 , about 0.5mm 2 Approximately 0.7 mm 2 , about 0.6mm 2 Approximately 0.8 mm 2 , about 0.7mm 2 Approximately 0.9 mm 2 , about 1mm 2 Approximately 1.25 mm 2 , about 1mm 2 from about 1.5 mm 2 , about 1.25mm 2 Approximately 1.75 mm 2 , about 1.5mm 2 Approximately 2 mm from 2 , about 1.75mm 2 Approximately 3 mm from 2 , or about 2 mm 2 Approximately 4 mm from 2 In an example, the surface area of ​​the top surface 102 may be selected based on the maximum lateral dimension of the orifice 114, since increasing the maximum lateral dimension of the orifice 114 may increase the surface area of ​​the top surface 102. In an example, the surface area of ​​the top surface 102 may be selected to be relatively small, which may reduce the likelihood that the top surface 102 will contact the printed material during use and / or reduce adverse effects (e.g., smudging, dragging, or flattening) of the top surface 102 contacting the printed material.

[0024] In embodiments, as shown, the top surface 102 may be substantially flat. In embodiments, at least a portion of the top surface 102 may be non-flat, such as curved or tapered. An at least partially curved or tapered top surface 102 may reduce the likelihood of the top surface 102 contacting the printed material during use. For example, the nozzle assembly may not extend perpendicular to the printed material (as shown in FIGS. 11-13). By angling the printing system non-perpendicularly relative to the printed material, the curved or tapered portion of the top surface 102 may prevent portions of the top surface 102 from contacting the printed material that would likely protrude or contact the printed material if the top surface 102 were flat.

[0025] The bottom surface 104 is configured to contact one or more surfaces of the base ("base contact surface"). One example of a base contact surface is the base contact surface 1142 in FIG. 11. The bottom surface 104 can exhibit a surface topography that generally corresponds to the base contact surface. For example, the bottom surface 104 can exhibit a substantially flat topography if the base contact surface is also substantially flat. Selecting the bottom surface 104 to exhibit a surface topography that generally corresponds to the base contact surface can reduce the size of any gaps that exist between the bottom surface 104 and the base contact surface. Any gaps that exist between the bottom surface 104 and the base contact surface can allow printing material to leak between the bottom surface 104 and the base contact surface. Printing material that leaks between the bottom surface 104 and the base contact surface can cause material to be ejected from portions of the nozzle assembly other than the orifice 114. Leaking of printing material between bottom surface 104 and the base contact surface may further contaminate the printing material. For example, the leaked printing material may harden or may be compositionally different from the printing material that subsequently flows through conduit 112, either of which may mix with the printing material flowing through conduit 112 and cause printing defects. In an embodiment, bottom surface 104 may be substantially parallel to top surface 102.

[0026] At least a portion of the side 106 is non-vertical (e.g., extends in a plane that intersects the central axis 118 of the nozzle 100). For example, the side 106 can be non-vertical if it is non-parallel (e.g., transverse) to the central axis 118 of the nozzle 100 (the axis extending from the center of the top surface 102 to the center of the bottom surface 104). For example, at least about 55%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, or at least about 100% (as shown), or in a 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 106 is non-vertical. The percentage of the side 106 that is non-vertical can be calculated by multiplying at least one of the surface area percentages, the length L of the nozzle 100 over which the side 106 is non-vertical, and the surface area of ​​the nozzle 100. N The non-perpendicularity may relate to the proportion of the non-perpendicular side 106 that is greater than 55%, or the length of the side 106 measured along the shortest path (with or without any chamfer) from the top surface 102 to the bottom surface 104 that extends along the outer portion of the side 106 that is non-perpendicular. Selecting the proportion of the non-perpendicular side 106 to be greater than 55%, and even increasing the proportion of the non-perpendicular side 106, can assist in attaching the nozzle 100 to a base. For example, as discussed in more detail below, the nozzle 100 can be placed in a recess defined in the base and attached to the base. The recess can be smaller than one or more dimensions of the nozzle 100 (e.g., the largest lateral dimension D NA recess opening (smaller than the recess opening) can be defined (e.g., after swaging) to prevent the nozzle 100 from leaving the recess and secure the nozzle 100 to the base. Increasing the percentage of the side surface 106 that is non-perpendicular can allow the surfaces of the base that define the recess to contact a greater portion of the side surface 106, thereby better securing the nozzle 100 to the recess. Furthermore, increasing the percentage of the nozzle 100 that is non-perpendicular, such as the portion of the nozzle 100 closer to the bottom surface 104, increases the distance that the top surface 102 can protrude from the base. Examples of angles at which the side surface 106 can extend relative to the central axis 118 are disclosed in U.S. Provisional Application No. 63 / 171,708, filed April 7, 2021, the disclosure of which is incorporated herein by reference in its entirety.

[0027] In an embodiment, the side surface 106 has a generally conical surface. However, the side surface 106 can also have, without limitation, multiple surfaces or non-conical surfaces. In an example, the side surface 106 can have multiple surfaces, where the angle at which each surface of the side surface 106 extends relative to the central axis 118 can vary. The multiple side surfaces 106 can aid in attaching the nozzle 100 to a 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.

[0028] As discussed above, nozzle 100 has a chamfer 108 extending from bottom surface 104 to nozzle side surface 106. Any of the chamfers disclosed herein have one or more transition surfaces between two other surfaces and, unless otherwise disclosed herein, can have one or more curved surfaces (e.g., curved surfaces exhibiting 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 flat surfaces. Chamfer 108 can make it easier to insert nozzle 100 into a recess defined by a base to which it is attached, compared to inserting nozzle 100 if nozzle 100 had a sharp corner between bottom surface 104 and side surface 106 (e.g., a surface exhibiting an average radius of curvature that is less than 0.2 mm).

[0029] At least a portion of at least one of the top surface 102, bottom surface 104, sides, or any other external surface (e.g., chamfer 108) of the nozzle 100 has a thickness 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 The top surface 102 may be polished to exhibit a root mean square (RMS) surface roughness of about 15 nm to about 50 nm, about 30 nm to about 75 nm, about 50 nm to about 100 nm, about 75 nm to about 200 nm, about 100 nm to about 300 nm, about 200 nm to about 500 nm, about 300 nm to about 750 nm, about 500 nm to about 1 μm, about 750 nm to about 1.5 μm, about 1 μm to about 2 μm, or about 1.5 μm to about 3 μm. In an illustrative 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, the polished portion of the top surface 102 can reduce the likelihood of pulling on a portion of the printed material in the direction in which the nozzle 100 moves relative to the printed material when the top surface 102 contacts the printed material. In an illustrative example, by contacting a polished portion of the top surface 102 against the printed material, the top surface 102 can impart a smooth surface to the printed material that can be used to influence (e.g., improve) the adhesion of a subsequent layer of printed material onto the already printed material and / or to impart a desired shape to the printed material. In an illustrative example, polishing the bottom surface 104 and / or the sides 106 to any of the RMS surface roughnesses discussed above can reduce gaps that would otherwise form between the bottom surface 104 and / or the sides 106 and the base. Reducing gaps between the bottom surface 104 and / or the sides 106 and the base can prevent or inhibit leakage of printed material between the nozzle 100 and the base.

[0030] 1B , conduit surface 110 has a portion closest to top surface 102 (the "top of the conduit surface"). The top of conduit surface 110 has a portion of conduit surface 110 that extends a non-zero distance from top surface 102 (e.g., first conduit surface 110a) and / or a chamfer that extends between top surface 102 and conduit surface 110 (e.g., chamfer 724 or 824 shown in FIGS. 7 and 8). For example, the distance that the top of conduit surface 110 extends may be at least 0.25 mm, at least about 0.5 mm, or at least 1 mm.

[0031] A portion of the conduit surface 110 (e.g., the top or upper portion near the orifice 114) can be non-perpendicular (e.g., extend in a plane that intersects the central axis 118 of the nozzle 100). For example, the cross section of the top of the conduit surface 110 may be non-parallel to the central axis 118 of the nozzle 100 (e.g., set laterally). Stated differently, this portion of the conduit surface 110 may extend laterally or radially inward and / or laterally or radially outward relative to the central axis 118. Such portions of the conduit surface 110 that extend at one or more oblique angles relative to the central axis 118 may define surfaces that gradually expand or contract the cross-sectional volume of the orifice 114.

[0032] Thus, the top of the conduit surface 110 may not exhibit a generally cylindrical or rectangular shape because these shapes have vertical surfaces (e.g., aligned with the central axis 118). Surprisingly, it has been found that the non-vertical nature of the top of the conduit surface 110 can reduce the force required to extrude printing material through the conduit 112 compared to the force required to extrude printing material through the conduit if the top of the conduit surface 110 were vertical. The non-vertical nature of the top of the conduit surface 110 can facilitate a more gradual reduction in the width of the conduit 112 (e.g., measured perpendicular to the central axis 118) than would be the case if the top of the conduit surface 110 were vertical. It is presently believed that at least a partial gradual reduction in the width of the conduit 112 can reduce the force required to move printing material through the conduit 112. Reducing the force required to extrude printing material through the conduit 112 can further reduce the likelihood of printing material leaking between the nozzle 100 and the base. Additionally, it has been surprisingly found that the non-vertical nature of the conduit 112 can reduce the likelihood of the conduit 112 becoming clogged when flowing printing material through the conduit 112.

[0033] Furthermore, it has been unexpectedly found that the non-vertical nature of the top of the conduit surface 110 can facilitate more complete removal of printed material from the conduit 112. For example, printed material may be removed from the conduit 112 after the printing process is completed to prevent the printed 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, printed material may be removed from the conduit 112 after printing a first material from the nozzle 100 or before printing a second printed material different from the first material from the nozzle 100, thereby preventing the first printed material from contaminating the second material. It has been found that when the top of the conduit surface 110 is vertical, removing printed material from the conduit 112 results in the formation of strings of printed material residing within or extending from the conduit 112. At least a portion of the string of printed material may remain in the conduit 112 after the remainder of the printed material is removed, and the string of printed material remaining in the conduit 112 may be difficult to completely remove from the conduit 112. However, it has been unexpectedly found that the non-vertical nature of the top of the conduit surface 110 can prevent the formation of strings of printed material, or at least reduce the amount of strings of printed material formed compared to the amount of strings of printed material formed when the top of the conduit surface 110 is vertical. If strings of printed material form during the removal of the printed material, the non-vertical nature of the top of the conduit surface 110 allows more strings to be removed from the conduit 112 than if the top of the conduit surface 110 were vertical. Without being bound by theory, it is currently believed that when the conduit surface 110 includes multiple conduit surfaces, the intersection locations (i.e., corners or edges) between different surfaces of the conduit surface 110 cause the strings to form. The non-vertical nature of the apex of conduit surface 110 may make the intersection locations between different surfaces of conduit surface 110 less noticeable (e.g., the difference between angle θ and angle φ may be smaller) compared to when the apex of conduit surface 110 is vertical.It is believed that the less pronounced intersection location created by the non-vertical nature of the top of conduit surface 110 reduces string formation and allows for more complete removal of the printed material compared to when the top of conduit surface 110 is vertical. The less pronounced intersection location may also reduce the force required to push the printed material through conduit 112, which may further reduce the likelihood of the printed material clogging during operation.

[0034] As shown in FIG. 1B , the conduit surface 110 has a first conduit surface 110a and a second conduit surface 110b. The first conduit surface 110a can extend from the top surface 102 (as shown) or can extend from a chamfer extending between the top surface 102 and the conduit surface 110a to the second conduit surface 110b (as shown in FIGS. 7 and 8 ). The second conduit surface 110b extends from the first conduit surface 110a toward (e.g., to) the bottom surface 104 (as shown). Configuring the conduit surface 110 to have multiple surfaces reduces the visibility of edges formed between these surfaces. Such a conduit surface reduces the visibility of edges formed between the conduit surface 110 and the bottom surface 104. Thus, multiple conduit surfaces 110 can provide one or more of the following advantages: reducing the force required to push the printing material through the conduit 112, reducing the likelihood of the printing material clogging during operation, and / or preventing strings of printing material from forming when removing the printing material from the conduit 112 or reducing the likelihood of strings of printing material forming compared to when the conduit surface 110 has only a single conduit surface.

[0035] In the illustrated example, first conduit surface 110a can at least partially form the apex of conduit surface 110. Thus, first conduit surface 110a can be non-perpendicular. In an example, as shown, first conduit surface 110a can form a generally frusto-conical shape. In such an example, first conduit surface 110a can extend at an angle θ relative to central axis 118. In an example, first conduit surface 110a can exhibit a generally converging shape (e.g., a generally tapered shape with curved sidewalls, such as sidewalls that form a concave or convex shape in cross section), a truncated generally polyhedral shape (e.g., the walls of the truncated generally polyhedral shape can extend at an angle θ relative to central axis 118), or any other suitable shape. It should be noted that generally truncated, generally polyhedral shapes and other shapes that may include intersecting surfaces in first conduit surface 110a may increase the likelihood of strings of printed material forming during removal of the printed material compared to when first conduit surface 110a exhibits intersecting surfaces, such as a frustoconical or generally converging shape. However, the edges of such shapes may reduce the likelihood of strings of printed material forming during removal of the printed material compared to when first conduit surface 110a exhibits a shape, such as a generally cylindrical shape.

[0036] It should be noted that in some examples, first conduit surface 110a can exhibit a shape that includes non-vertical and vertical surfaces, such as a truncated generally triangular prism shape. Such a shape can increase (compared to a shape that includes only vertical surfaces) or decrease (compared to a shape that does not include vertical surfaces) the force required to extrude printing material through conduit 112, the likelihood of clogging the printing material, and / or the likelihood of strings of printing material forming when removing the printing material from conduit 112.

[0037] When first conduit surface 110a extends at an angle θ relative to central axis 118 (e.g., when first conduit surface 110a exhibits a generally truncated conical or polyhedral shape), angle θ can 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 Alternatively, the angle θ may 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 may be selected based on one or more factors. In an illustrative example, the angle θ may be selected to be greater than about 4° because the first conduit surface 110a may begin to behave similarly to a vertical conduit surface if the angle θ is less than 4°. As used herein, the term "perpendicular" means that the angle θ is between 0° and 1°. In an example, the angle θ may be selected based on the method used to form the conduit 112, as only some methods of forming the conduit 112 can form the first conduit surface 110a at a particular angle θ relative to the central axis 118. In an example, the angle θ may be selected based on the angle φ at which the second conduit surface 110b extends relative to the central axis 118, as generally, the angle φ can be selected to be greater than the angle θ, thereby reducing the force required to extrude the printing material through the conduit 112.

[0038] The second conduit surface 110b may be non-perpendicular, thereby facilitating a generally reduced width of the conduit 112 along the path of the conduit 112 from the opening 116 to the orifice 114. In an example, the non-perpendicularity of the second conduit surface 110b may form a generally truncated conical shape. In such an example, the second conduit surface 110b may extend at an angle φ relative to the central axis 118. In an example, the second conduit surface 110b may assume a generally converging shape, a generally truncated polyhedral shape, a generally frustoconical shape, or any other suitable shape. The second conduit surface 110b may form the same shape as the first conduit surface 110a or a different shape.

[0039] If the second conduit surface 110b extends at an angle φ with respect to the central axis 118 (e.g., if the second conduit surface 110b exhibits a generally truncated conical or polyhedral shape), the angle φ can be about 5° or more, about 6° or more, about 7° or more, about 8° or more, about 9° or more, about 10° or more, about 12° or more, about 14° or more, about 18° or more, about 20° or more, about 25° or more, about 30° or more, about 35° or more, about 40° or more, about 45° or more, about 50° or more, about 55° or more, about 60° or more, about 65° or more, about 70° or more, or The angle φ may 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 may be selected based on one or more factors. In an example, the angle φ can be dependent on the angle θ of the first conduit surface 110a because, as discussed above, the angle φ is selected to be greater than the angle θ. In an example, the angle φ can be selected so that the opening 116 is sized to be comparable to the size of the passageway in the base (e.g., passageway 1158 in FIG. 11). In such an example, the angle φ is selected such that the length L of the nozzle 100 is N, and the length that first conduit surface 110a extends along central axis 118, since these factors can affect the angle φ required to form an opening 116 that is comparable in size to the passageway size in the base.

[0040] 1C is an enlarged view of a portion of nozzle 100 within circle 1C shown in FIG. 1B, according to an embodiment. As shown in FIG. 1C, first conduit surface 110a and second conduit surface 110b can intersect at intersection location 120. As discussed above, intersection location 120 can cause strings of printed material to form when the printed material is removed from conduit 112. Intersection location 120 can be curved, which can make intersection location 120 less noticeable and reduce the likelihood of strings of printed material being formed by intersection location 120 when the printed material is removed from conduit 112, compared to when intersection location 120 is non-curved. Intersection location 120 may be curved if it exhibits a radius of curvature of about 0.1 mm or more, about 0.15 mm or more, about 0.2 mm or more, about 0.3 mm or more, about 0.4 mm or more, about 0.5 mm or more, about 0.6 mm or more, about 0.7 mm or more, about 0.8 mm or more, about 0.9 mm or more, about 1 mm or more, or in 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, or about 0.8 mm to about 1 mm. Generally, increasing the average radius of curvature of intersection location 120 can reduce the likelihood of intersection location 120 forming a string of printed material.

[0041] FIG. 1D is an enlarged view of a portion of the nozzle 100 within the circle 1C shown in FIG. 1B , according to another embodiment. As shown in FIG. 1D , the first conduit surface 110a and the second conduit surface 110b intersect at an intersection location 120′ that is not curved. The intersection location 120′ is non-curved if the intersection location 120′ exhibits an average radius of curvature that is less than 0.1 mm. A non-curved intersection location 120′ may increase the likelihood of the intersection location 120′ forming a string of printing material when removing the printing material from the conduit 112, compared to the intersection location 120 shown in FIG. 1C . However, forming the intersection location 120′ may reduce the manufacturing effort required to form the nozzle 100, compared to forming the intersection location 120 shown in FIG. 1C . Furthermore, the intersection location 120′ forms a structure that increases the likelihood of the intersection location 120′ wearing at a higher rate compared to the remainder of the nozzle 100 as printing material flows through the conduit 112. Wear at the intersection location 120' can cause the intersection location 120' to curve relatively quickly to reduce the likelihood of the intersection location 120' forming strings of printed material.

[0042] The conduit surfaces disclosed herein can have three or more conduit surfaces, such as a first conduit surface, a second conduit surface, and at least one additional conduit surface (e.g., a third conduit surface). The first conduit surface can extend from or near the top surface of the nozzle to the second conduit surface, which can extend between the first conduit surface and the at least one additional conduit surface, which can extend from the second conduit surface to or near the bottom surface. Figure 2 is a schematic cross-sectional view of a nozzle 200, according to an embodiment. Unless otherwise disclosed herein, the nozzle 200 can have one or more features that are equal to or substantially similar to any of the features of one or more of the other nozzle embodiments disclosed herein, including, but not limited to, the features of the nozzle 200. For example, the nozzle 200 may have a top surface 202 , a bottom surface 204 , at least one side surface 206 , and a plurality of conduit surfaces 210 that define the conduit 112 .

[0043] The conduit surface 210 of the nozzle 200 has a first conduit surface 210 a, a second conduit surface 210 b, and a third conduit surface 210 c. Having the third conduit surface 210 c also reduces the edges formed between the conduit surfaces 210, thereby reducing the amount of strings of material formed when removing the printed material and also reducing the force required to extrude the printed material through the conduit 212.

[0044] First conduit surface 210a extends from or near top surface 202 at an angle θ relative to central axis 218. Second conduit surface 210b extends between first conduit surface 210a and third conduit surface 210c at an angle φ relative to central axis 218 that is greater than angle θ. Third conduit surface 210c extends from second conduit surface 210c toward (e.g., to or near) bottom surface 204 at an angle α relative to central axis 218 that is greater than angle φ. Angles θ, φ, and α can include any of the angles discussed above.

[0045] It should be noted that the nozzle 200 can also have one or more additional conduit surfaces in addition to the first conduit surface 210a, the second conduit surface 210b, and the third conduit surface 210c. The additional conduit surface can extend from the third conduit surface 210c toward (e.g., to) the bottom surface 204. The additional conduit surface can further reduce edges formed between the conduit surfaces 210, reduce the amount of strings of material formed when removing the printed material, and further reduce the force required to extrude the printed material through the conduit 212.

[0046] As discussed above, the conduit surfaces disclosed herein can have curved surfaces, such as convex and concave curved surfaces. Figures 3 and 4 each show cross-sectional views of different nozzle embodiments, each having a curved conduit surface. Unless otherwise disclosed herein, the nozzles shown in Figures 3 and 4 can have one or more features that are equal to or substantially similar to any one or more features of the nozzles disclosed herein, including, but not limited to, a top surface, a bottom surface, sides, and a conduit surface that defines a conduit.

[0047] 3 , the nozzle 300 can have a conduit surface 310 that exhibits a convex curvature. The convex curvature of the conduit surface 310 can be configured to allow the conduit surface 310 to have only a non-vertical surface at the top of the conduit surface 310. Thus, the conduit surface 310 can achieve one or more of the following: reducing the likelihood of the printing material clogging the conduit 312, reducing the pressure required to force the printing material through the conduit 312, or reducing the likelihood of strings of printing material forming when removing the printing material from the conduit 312 compared to when the conduit surface 310 has a vertical surface. In some examples, the lateral dimension at and near the opening 316 decreases at a faster rate than when the conduit surface 310 exhibits a truncated cone shape as shown in FIGS. 1B and 2 . The greater change in lateral dimension at and near the opening 316 may increase the force required to move the printing material through the conduit 312 near the opening 316 compared to when the conduit surface 310 exhibits a truncated cone shape.

[0048] 4, the nozzle 400 can have a conduit surface 410 that exhibits a concave curvature. The concave curvature of the conduit surface 410 can be configured to allow the conduit surface 410 to have only a non-vertical surface at the top of the conduit surface 410. Thus, the conduit surface 410 can achieve one or more of the following: reducing the likelihood of the printing material clogging the conduit 412, reducing the pressure required to extrude the printing material through the conduit 412, or reducing the likelihood of strings of printing material forming when removing the printing material from the conduit 412 compared to when the conduit surface 410 has a vertical surface. In some examples, the lateral dimensions at and near the orifice 414 decrease at a faster rate than when the conduit surface 410 exhibits a truncated conical shape as shown in FIGS. 1B and 2. The large rate of change in lateral dimension at and near the orifice 414 can increase the force required to move the printing material through the conduit 412 near the orifice 414 compared to when the conduit surface 410 exhibits a truncated cone shape.

[0049] During operation of any of the nozzles disclosed herein, the printing material may be heated to maintain the printing material in a fluid state (e.g., a flowable state) and to control the viscosity of the printing material. The printing material may be heated by heating the nozzle and then transferring 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 temperature gradients within the printing material) is determined, at least in part, by the ratio of the nozzle surface area (surface area of ​​the orifice and conduit faces) that directly contacts the printing material to the volume of the conduit. In an example, increasing the nozzle surface area relative to the conduit volume can make the printing material more effective (e.g., reduce the temperature to which the nozzle needs to be heated and / or reduce temperature gradients within the printing material). In an example, decreasing the nozzle surface area relative to the conduit volume can make the printing material less effective. In such an example, the nozzle 100 may need to be heated to a higher temperature to ensure that the entire printing material exhibits at least a certain temperature.

[0050] As shown in FIG. 1A , the orifice 114 can have a generally circular shape at or near the apex 102. The conduit 112 of the nozzle 100 can also have a generally circular shape ("in-plane shape") when intersecting a reference plane oriented perpendicular to the central axis 118. This is because forming the conduit 112 and orifice 114 to have the same general shape can facilitate manufacturing of the nozzle 100. The generally circular in-plane shape of the orifice 114 and conduit 112 of the nozzle 100 can reduce the ratio of the surface area of ​​the nozzle 100 in contact with the printing material to the volume of the conduit 112 compared to a non-circular in-plane shape. Thus, in some examples, the nozzles disclosed herein can have orifices and / or conduits that have a non-circular in-plane shape to increase the ratio of the surface area of ​​the nozzle in contact with the printing material to the volume of the conduit. 5 and 6 are top views of nozzles 500 and 600, respectively, according to different embodiments, each having an orifice with a non-circular in-plane shape. For example, nozzle 500 is shown as having an orifice 514 with a generally six-pointed star in-plane shape relative to a central axis 518, and nozzle 600 is shown as having an orifice 614 with a generally pentagonal in-plane shape relative to a central axis 618. Although not shown, either conduit 512 of nozzle 500 or conduit 612 of nozzle 600 can have any non-circular in-plane shape, such as an in-plane shape that is substantially similar to the shape of its orifice, respectively, for ease of manufacturing. The non-circular in-plane shapes of orifices 514, 614 and conduits 512, 612 of nozzles 500, 600 can improve the effectiveness of nozzles 500, 600 in heating printing material flowing through the nozzles, compared to nozzle 100 shown in FIG. 1A.Any of the orifices and / or conduits of any of the nozzles disclosed herein can exhibit any non-circular in-plane shape (excluding a generally six-pointed star in-plane shape or a generally pentagonal in-plane shape), such as, but not limited to, a generally elongated (e.g., elliptical) in-plane shape, a generally polygonal in-plane shape, a generally semicircular in-plane shape, a generally triangular in-plane shape, a generally rectangular (e.g., square) in-plane shape, a generally hexagonal in-plane shape, a generally heptagonal in-plane shape, a generally octagonal in-plane shape, a generally four-pointed star in-plane shape, a generally five-pointed star in-plane shape, or any other suitable non-circular in-plane shape.

[0051] As discussed above, the nozzles disclosed herein can have one or more chamfers extending from the top surface to at least one of the side surfaces or conduits. Figures 7 and 8 are schematic cross-sectional views of different nozzles according to different embodiments, each having a chamfer extending from its top surface to its side surfaces or conduit surfaces. Except as otherwise disclosed herein, the nozzles shown in Figures 7 and 8 can have one or more features that are equal to or substantially similar to any of the features of other nozzle embodiments disclosed herein, including but not limited to:

[0052] Referring to FIG. 7 , the nozzle 700 has at least one outer chamfer 722 extending from the top surface 702 to the side surface 706. The outer chamfer 722 can prevent the nozzle 700 from interfering with the printed material, or at least reduce the likelihood of this occurring compared to when the nozzle 700 does not have the outer chamfer 722. For example, the top surface 702 of the nozzle 700 may not be oriented perfectly parallel to the printed material for various reasons, such as a nozzle assembly in which the nozzle 700 does not extend perfectly parallel to the printed material or variations in the thickness of the printed material. For a substantially similar nozzle without the outer chamfer, a portion of its top surface may terminate closer to the printed material than its orifice would if the top surface of such a nozzle were not perfectly parallel to the printed material. The portion of the top surface closer to the printed material compared to the orifice is more likely to contact or interfere with the printed material. This is because the nozzle orifice can be configured to be positioned close to the printed material to improve the resolution of the printed material. Contacting the top surface of the nozzle with the printed material can deform (e.g., scrape or scratch) the printed material, remove or reduce one or more adhesion features formed on the printed material (e.g., a polished surface, one or more grooves, or one or more protrusions), or pull the printed material (relative to the printed material) in the direction of nozzle movement. However, the outer chamfer 722 of the nozzle 700 reduces the maximum distance that the top surface 702 of the nozzle 700 can extend past the orifice 714 of the nozzle 700 if the top surface 702 is not perfectly parallel to the printed material. Reducing the maximum distance that the top surface 702 extends past the orifice 714 can prevent, or at least reduce, the likelihood that the top surface 702 will contact or interfere with the printed material.

[0053] The outer chamfer 722 has 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 and can be expressed as width W C and length L C are independently about 0.05 mm or more, about 0.075 mm or more, about 0.1 mm or more, about 0.125 mm or more, about 0.15 mm or more, about 0.2 mm or more, about 0.25 mm or more, about 0.3 mm or more, about 0.4 mm or more, about 0.5 mm or more, about 0.6 mm or more, about 0.7 mm or more, about 0.8 mm or more, about 0.9 mm or more, about 1 mm or more, or about 0.05 mm to about 0.1 mm, about 0.075 mm to about 0.125 mm, It may be selected to be in the range of 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.

[0054] Width W C and length L C may be selected based on one or more factors. C and length L C are the width W C and length L C The width W may be selected based on the overall width and length of the nozzle 700 measured perpendicular to the C and length L C may be selected based on the angle of the side surface 706 extending relative to the central axis 718, as this angle may affect the angle of the outer chamfer 722 extending relative to the central axis 718. In the illustrative example, the width W C and length L Cmay be selected based on the hardness of nozzle 700, and more specifically, the difficulty of forming, grinding, or machining nozzle 700. For example, nozzle 700 may be formed from PCD, PcBN, or another superhard material that is difficult to form, grind, or machine. Thus, width W C and length L C may be chosen to be as large as necessary to avoid excessive manufacturing time, tooling, and / or associated costs.

[0055] The top surface 702 can exhibit a first surface area, and the outer chamfer 722 can exhibit a second surface area. In examples, the second surface area of ​​the outer chamfer 722 can 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%) (e.g., to reduce machining of the nozzle 700). In examples, the second surface area of ​​the outer chamfer 722 can be selected to be equal 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 that the nozzle 700 will contact the printed material. In an embodiment, the second surface area of ​​outer chamfer 722 may be about 25% to about 80% of the first surface area of ​​top surface 702 .

[0056] The nozzle 700 can have an inner chamfer 724 extending from the top surface 702 to the conduit surface 710. The inner chamfer 724 can increase the maximum lateral dimension (e.g., diameter) of the conduit 712 at the orifice 114. Using the inner chamfer 724 to increase the maximum lateral dimension of the conduit 712 at the orifice 714 can improve the consistency of the printed material dispensed from the nozzle 700 (e.g., reduce the variability in the lateral dimensions of the printed material), thereby improving the resolution of the printed material. The inner chamfer 724 can extend from the top surface 702 to the conduit surface 710. C and L CThe central axis 718 may have a width and length measured perpendicular and parallel to the central axis 718, respectively, that fall within any of the ranges discussed above in relation to the width and length.

[0057] The outer chamfer 722 and the inner chamfer 724 are shown as generally conical surfaces. However, the nozzles disclosed herein can have inner and outer chamfers that exhibit generally curved, dome-shaped, convex, concave, oval, toroidal, or spheroidal surfaces. For example, with reference to FIG. 8 , a nozzle 800 has an outer chamfer 822 extending from a top surface 802 to a side surface 806 and an inner chamfer 824 extending from the top surface 802 to a conduit surface 810. The outer chamfer 822 and the inner chamfer 824 can exhibit one or more features that are the same as or substantially similar to one or more features of the outer chamfer 722 and the inner chamfer 724 shown in FIG. 7 , except that the outer chamfer 822 and the inner chamfer 824 have convex curved surfaces (e.g., when viewed in cross section).

[0058] It is currently believed that the generally conical outer chamfer 722 may reduce the likelihood of the nozzle 700 contacting the printed material compared to a curved or annular outer chamfer 822 because the slope of the conical outer chamfer 722 adjacent the top surface 702 is greater than the slope of the curved outer chamfer 822 adjacent the top surface 802. It is currently believed that the curved inner chamfer 824 shown in FIG. 8 may improve the consistency of printed material dispensed from the nozzle 800 compared to the conical inner chamfer 724 shown in FIG. 7 because the edge between the inner chamfer 724 and the conduit surface 710 is more noticeable when the inner chamfer is conical.

[0059] 7 and 8 are shown as having only a conical or curved chamfer extending from their top surface. However, it should be noted that the nozzles disclosed herein can also have a curved outer chamfer and a conical inner chamfer, or a conical outer chamfer and a curved inner chamfer. It should also be noted that the nozzles disclosed herein can have only one of the outer chamfer, the inner chamfer, or neither.

[0060] As discussed above, nozzles disclosed herein can be configured to impart one or more adhesion-enhancing features to printed materials formed using such nozzles. In embodiments, as discussed above, one or more abrasive surfaces of the nozzles can be configured to contact the printed material to provide a smooth surface that may, in some circumstances, improve the adhesion of subsequent layers deposited thereon. In other embodiments, nozzles disclosed herein can be configured to increase the surface area of ​​the printed material formed by the nozzles, which may, in some circumstances, improve the adhesion of subsequent layers deposited thereon. Figures 9A and 10 are schematic cross-sectional views of nozzles 900, 1000 configured to increase the surface area of ​​printed material formed by the nozzles, according to different embodiments. Except as otherwise disclosed herein, the nozzles 900, 1000 shown in Figures 9A and 10 are equivalent to or substantially similar to any of the nozzles disclosed herein.

[0061] 9A , nozzle 900 has at least one top surface 902, at least one side surface 906, and at least one conduit surface 910. Nozzle 900 has (e.g., defines) one or more passages 926 extending inward from top surface 902. Passages 926 are configured to form one or more protrusions in the printed material, thereby increasing the surface area of ​​the printed material and, as discussed above, can improve adhesion with a subsequent layer of printed material deposited thereon. Passages 926 can form protrusions in the printed material when at least one of the printed materials rubs against passage 926 upon dispensing from nozzle 900, or top surface 902 can contact the printed material after deposition of the printed material.

[0062] The nozzle 900 can have any number of passages 926 formed thereon. For example, the nozzle 900 can have 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more than 10 passages 926 formed thereon. The number of passages 926 can affect at least one of the number of protrusions formed on the printed material, the size of the passages 926 formed on the nozzle 900, which determines the size of the protrusions formed on the printed material, or the number of directions in which the nozzle 900 can move relative to the printed material.

[0063] In an embodiment, as shown, the passages 926 may be radially extending passages 926 extending from the conduit surface 910 to the side surface 906. In such an embodiment, only the passages 926 extending substantially parallel to the direction of movement of the nozzle 900 during operation may form protrusions in the printed material. In another embodiment (not shown), the passages may include multiple substantially parallel passages. In such an embodiment, the substantially parallel passages may be oriented substantially parallel to the direction of relative movement between the nozzle 900 and the printed material during operation, thereby allowing each passage to form more protrusions in the printed material than would be the case with a radially extending passage 926. In another embodiment, the printing device to which the nozzle 900 is mounted (e.g., via a base) may be configured to rotate the nozzle 900 such that the passages may be oriented in a selected orientation relative to the expected direction of relative movement between the nozzle 900 and the printed material. Rotating the nozzle 900 can allow one or more of the radially extending passages 926 or multiple substantially parallel passages (not shown) to be generally parallel to an expected direction of relative movement between the nozzle 900 and the printed material during operation. The printing device can be configured to rotate the nozzle 900 to orient one or more of the passages 926 to be generally parallel to the direction of movement between the nozzle 900 and the printed material.

[0064] 9B is an enlarged schematic cross-sectional view of a portion of nozzle 900 from circle 9B shown in FIG. 9A, having passageway 926, according to an embodiment. As shown in FIG. 9B, passageway 926 has a width W measured between opposing portions of top surface 902 that define passageway 926. R and width W R and a maximum depth D measured perpendicular to the width W. Rand maximum depth D is, independently, about 0.05 mm or more, about 0.075 mm or more, about 0.1 mm or more, about 0.125 mm or more, about 0.15 mm or more, about 0.2 mm or more, about 0.25 mm or more, about 0.3 mm or more, about 0.4 mm or more, about 0.5 mm or more, about 0.6 mm or more, about 0.7 mm or more, about 0.8 mm or more, about 0.9 mm or more, about 1 mm or more, or about 0.05 mm to about 0.1 mm, about 0.075 mm to about 0.12 The width W may be selected to be in the range of about 0.5 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. R The width W of the passage 926 and the depth D can be selected based on the desired size of the protrusion formed in the printed material, since such protrusion can have a size corresponding to the size of the passage 926. The desired size of the protrusion can be selected based on the material forming the printed material. For example, the width W of the passage 926 and the depth D can be selected based on the material forming the printed material. R Alternatively, one or more of the depths D may be selected to increase the surface area of ​​the protrusions, which may be advantageous if the material forming the printed material exhibits poor adhesion.

[0065] The passageway 926 may be defined by one or more passageway surfaces 928. In an example, the passageway 926 may have a generally rectangular (e.g., square) cross-sectional shape. In such an example, the passageway surfaces 928 defining the passageway 926 may include two generally vertical passageway surfaces extending inward from the top surface 902 and a generally horizontal passageway surface extending between the vertical surfaces. Note that the passageway formed within any of the nozzles disclosed herein may have a non-rectangular cross-sectional shape. For example, FIGS. 9C and 9D are enlarged schematic cross-sectional views of portions of nozzles 900c and 900d, respectively, having passageways 926c and 926d, according to different embodiments. Except as 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 has a passageway 926c extending inward from top surface 902c with a generally triangular cross-sectional shape, and nozzle 900d has a passageway 926d extending inward from top surface 902d with a generally semicircular cross-sectional shape. The cross-sectional shapes of the passageways can be selected based on, for example, the materials forming the printed material. For example, various cross-sectional shapes of the passageways can affect the surface area of ​​the printed material and / or certain cross-sectional shapes of the passageways can improve adhesion between materials over other cross-sectional shapes.

[0066] 10 , nozzle 1000 has one or more protrusions 1030 extending upward from its top surface 1002. Optionally, protrusions 1030 may be configured to form one or more depressions in the printed material, which can increase the surface area of ​​the printed material and thereby improve adhesion with a subsequent layer of printed material deposited thereon, as discussed above. For example, protrusions 1030 can form depressions in the printed material when at least one of the following occurs: 1) the printed material rubs against protrusions 1030 as it is dispensed from nozzle 1000, or top surface 1002 contacts the printed material after deposition of the printed material.

[0067] The protrusion 1030 can have one or more features that are equal to or substantially similar to one or more features of the passageway 926, except that the protrusion 1030 extends outward from the top surface 1002 rather than inward. Illustratively, the nozzle 1000 can have one, two, three, four, five, six, seven, eight, nine, ten, or more than ten protrusions 1030 formed thereon. Illustratively, the protrusion 1030 can have multiple radially extending protrusions 1030 or multiple parallel protrusions 1030. In either embodiment, the printing device to which the nozzle 1000 is attached (e.g., via a base) can be configured to rotate the nozzle 1000. Illustratively, the protrusion 1030 can be configured to rotate the nozzle 1000 relative to the width W of the passageway 926 discussed above. R and maximum depth D. The width and maximum height of the protrusion 1030 may be selected based on the desired size of the recess to be formed in the printed material, since such recess can have a size corresponding to the size of the protrusion 1030. In illustrative examples, the protrusion 1030 may have a generally rectangular (e.g., square) cross-sectional shape, a generally triangular cross-sectional shape, a generally semicircular cross-sectional shape, or any other suitable cross-sectional shape. The cross-sectional shape of the protrusion 1030 may be selected based on the material forming the printed material, since various cross-sectional shapes of the protrusion 1030 can affect the surface area of ​​the printed material and / or certain cross-sectional shapes of the protrusion can improve adhesion between materials over other cross-sectional shapes.

[0068] As previously discussed, the nozzles disclosed herein may be attached to a base to form a nozzle assembly configured to be attached to a printing device. Figure 11 is a schematic cross-sectional view of a nozzle assembly 1132 having a nozzle 1100 attached to a base 1134, according to an embodiment. Except as otherwise disclosed herein, the nozzle 1100 may have one or more features that are equal to or substantially similar to one or more features of any of the nozzles disclosed herein, including, but not limited to,

[0069] The base 1134 has a nozzle portion 1136 configured to mount the nozzle 1100 and a mounting portion 1138 configured to mount the base 1134 to a printing device (not shown). The base 1134 can optionally have an intermediate portion 1140 between the nozzle portion 1136 and the mounting portion 1138.

[0070] The nozzle portion 1136 of the base 1134 defines a recess (not numbered) (occupied by the nozzle 1100) configured to receive the nozzle 1100. The recess is defined in part by a base contact surface 1142 configured to abut the bottom surface 1104 of the nozzle 1100. The base contact surface 1142 can exhibit a surface topography that generally corresponds to the surface topography of the bottom surface 1104 of the nozzle 1100. The corresponding surface topography of the base contact surface 1142 and the bottom surface 1104 can be configured to prevent, or at least impede, leakage of printing material between the nozzle 1100 and the base 1134. The recess is further defined in part by at least one recess side surface 1144. The recessed side surfaces 1144 can define recessed openings 1146 that allow the orifice 1114 of the nozzle 1100 to be exposed (e.g., not covered by the base 1134) and can further allow a portion of the nozzle 1100 to extend beyond the end face of the base 1134. In other words, the recessed side surfaces 1144 can be configured not to abut or cover at least a portion (e.g., the entirety) of the top surface 1102 of the nozzle 1100. The recessed side surfaces 1144 can have a shape that corresponds to the shape of the side surfaces 1106 of the nozzle 1100, thereby preventing or at least impeding leakage of printed material between the recessed side surfaces 1144 and the side surfaces 1106 of the nozzle 1100. The recess may optionally have at least one chamfered surface (not shown) extending between the base contact surface 1142 and the recess side surface 1144 that is sized and configured to abut against an optional chamfer (not shown) of the nozzle 1100 extending between the bottom surface 1104 and the side surface 1106 of the nozzle 1100.

[0071] The nozzle portion 1136 can have at least one wall 1148 extending from the remainder of the nozzle portion 1136 (e.g., the tapered surface 1150 or the gripping structure). The wall 1148 forms at least a portion of the recess side 1144. In one embodiment, the wall 1148 can be configured to allow the base 1134 to secure the nozzle 1100 thereto via swaging. For example, the wall 1148 can be initially vertical or otherwise oriented (not shown) such that the lateral dimension of the recess opening 1146 is wide enough to properly position the nozzle 1100 within the recess (e.g., the bottom surface 1104 of the nozzle 1100 abuts the base contact surface 1142). The walls 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 to pass the nozzle 1100 therethrough. Thus, the walls 1148 may be deformed inwardly to secure and / or position the nozzle 1100 relative to the base 1134. The walls 1148 may also be deformed inwardly to cause the recess sides 1144 to abut the sides 1106 of the nozzle 1100.

[0072] The nozzle portion 1136 can have a tapered surface 1150 extending outward from the recess opening 1146 and / or the wall 1148. The tapered surface 1150 can have one or more flat and / or curved surfaces. As shown in FIG. 11 , the tapered surface 1150 is not perpendicular to the longitudinal axis of the base 1134 (e.g., relative to a central axis, not shown), but instead is angled and / or curved toward the mounting portion 1138 of the base 1134. The tapered shape 1150 can prevent the base 1134 from contacting the printed material, or at least reduce the likelihood of this compared to if the base 1134 had a non-tapered surface.

[0073] The nozzle portion 1136 can have one or more gripping structures configured to assist in attaching and detaching the base 1134 to a printing device. In embodiments, as described below, the nozzle portion 1136 can be configured to be threadably attached to a printing device (not shown) and can have “wrench flats” sized and configured to allow the nozzle assembly to be rotated with a wrench. In some embodiments, the gripping structures can have a generally square, hexagonal (as shown), other suitable wrench flat shape, or other suitable shape that allows for gripping and twisting a portion of the nozzle portion 1136 with fingers, pliers, a wrench, a socket, or other tool. In some embodiments, the gripping structures can have one or more textured surfaces (cylindrical, wrench flats, or other suitable shape) or high-friction materials that also allow for gripping the nozzle portion 1136 with fingers, pliers, or other tool.

[0074] As discussed above, base 1134 has mounting portion 1138. Mounting portion 1138 is configured to mount base 1134 to a printing device. In embodiments, as shown, mounting portion 1138 is configured to be threadably mounted to a printing device. In such embodiments, mounting portion 1138 can define one or more helical threads 1154. In embodiments, mounting portion 1138 can include a magnet, can have a recess configured to receive a pin, and can be configured to be press-fit into a printing device, brazed to a printing device, soldered to a printing device, adhesively attached to a printing device, or attached to a printing device using any other suitable technique. In embodiments, base 1134 can be configured to be selectively mounted to and removed from a printing device, respectively. In such embodiments, base 1134 may be attached to and detached from a printing device without substantially damaging base 1134 or the printing device. Selective attachment of base 1134 to a printing device may enable the printing device to be used with a variety of nozzle assemblies (e.g., nozzle assemblies having orifices of various sizes) or to allow for replacement of worn nozzle assemblies. In embodiments, base 1134 may be configured for selective attachment to base 1134.

[0075] The base 1134 has at least one passage surface 1156 that defines a passage 1158. The passage 1158 is configured to extend from a conduit (e.g., an opening of the conduit) of the nozzle 1100 to an exterior portion of the base. The passage 1158 can be fluidly connected to a printing material source (e.g., another conduit or tank) of the printing device when the base 1134 is attached to the printing device. Thus, printing material from the printing material source can flow from the printing material source through the passage 1158 to the conduit 1112 of the nozzle 1100. In an embodiment, the passage 1158 is centrally located within the base 1134 and extends from the base contact surface 1142 to an opposing surface of the attachment portion 1138. However, it should be noted that the passage 1158 may not exhibit one or more of the following (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): being centrally located, extending from the base contact surface, or extending to the opposing surface of the mounting portion 1138.

[0076] As discussed above, the nozzle 1100 may be secured to the base 1134 via swaging or other suitable modification of the base 1134 to achieve retention of the nozzle 1100. However, the nozzle 1100 may be secured to the base 1134 using one or more other techniques, such as brazing, soldering, adhesive attachment, press fit, threaded attachment, or other forms of attachment of the nozzle 1100 to the base 1134. Depending on the method or methods used to attach the nozzle 1100 to the base 1134, a recess may be eliminated from the base 1134, and the nozzle 1100 may simply be attached to the outer surface of the base 1134. Another example of attaching the nozzle 1100 to the base 1134 is disclosed in U.S. Provisional Application No. 63 / 171,708, filed April 7, 2021, the disclosure of which is incorporated herein by reference in its entirety. If the nozzle 1100 includes a PCD, the method or methods used to attach the nozzle 1100 to the base 1134 may be selected to include one or more non-thermal attachment techniques (i.e., attachment techniques that require heating the nozzle 1100) or attachment techniques that heat the nozzle 1100 to temperatures of up to 700° C. This is because PCDs can begin to degrade if exposed to temperatures above 700° C.

[0077] As discussed 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 will contact the printed material and smear, displace, or otherwise adversely affect the printed material. In embodiments, the distance d may 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 between about 0.1 mm and about 0.5 mm, between about 0.25 mm and about 0.75 mm, between about 0.5 mm and about 1 mm, between about 0.75 mm and about 1.25 mm, between about 1 mm and about 1.5 mm, between about 1.25 mm and about 1.75 mm, The distance d may be selected to be in the range of 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 embodiments, 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 percentage of the side 1106 that is non-vertical, 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.

[0078] As discussed above, the nozzle 1100 can be heated during operation to control the temperature of the printing material (e.g., to maintain the printing material in a fluid state and / or to control the viscosity of the printing material). Generally, heating the nozzle 1100 involves heating the base 1134 with a printing device, transferring heat entering the base 1134 to the nozzle 1100, and transferring heat entering the nozzle 1100 to the printing material. The thermal conductivity of the nozzle 1100 and base 1134 affects the effectiveness and consistency of heating the printing material. For example, reducing the thermal conductivity of the nozzle 1100 and base 1134 will cause portions of the nozzle 1100 and base 1134 closest to the heating device of the printing device to experience higher temperatures than portions of the nozzle 1100 and base 1134 that are farther away from the heating device. This temperature gradient will heat the printing material to different temperatures depending on the portion of the nozzle assembly 1132 through which the printing material is flowing. This varying temperature may result in portions of the printing material being heated to a temperature that is too low to maintain the printing material in a fluid state or to maintain the viscosity of the printing material, and / or may require portions of the printing material to be heated to an excessively high temperature (which may cause the printing material to burn). Therefore, it is beneficial to select materials for the nozzle 1100 and base 1134 to improve their thermal conductivity to reduce any temperature gradients.

[0079] In an embodiment, nozzle 1100 may be formed from PCD or PcBN, materials that exhibit extremely high thermal conductivity or wear resistance. In such an embodiment, base 1134 may be formed from a material, such as brass or steel, that exhibits lower thermal conductivity than PCD and PcBN. The volume of nozzle 1100 may be increased to mitigate the effects of the low thermal conductivity of base 1134. For example, at least some conventional carbide nozzles have a volume of approximately 6.5 mm. 3 Nozzle 1100 (and any of the nozzles disclosed herein) exhibits the following volume: approximately 7.5 mm 3 Above, about 8mm 3 Above, about 9mm 3Above, about 10 mm 3 or more, about 11mm 3 Above, about 12 mm 3 Above, about 13 mm 3 Above, about 15mm 3 Over 17.5mm 3 or more, about 20mm 3 The above is approximately 22.5 mm 3 or more, about 25mm 3 or more, about 30mm 3 or more, about 35mm 3 Above, about 40 mm 3 Above, about 40 mm 3 or more, about 45mm 3 Above, about 50 mm 3 or more, about 60mm 3 or more, about 70mm 3 or more, about 80mm 3 Above, about 90mm 3 Above, about 100mm 3 or more, about 250mm 3 Above, about 500mm 3 or more, about 750mm 3 Over 1,000mm 3 Over 2,500mm 3 Over 5,000mm 3 The above is approximately 7,500 mm 3 More than or about 7.5 mm 3 Approximately 9 mm from 3 , approximately 8 mm 3 Approximately 10 mm from 3 , approximately 9 mm 3 Approximately 11 mm 3 , about 10mm 3 Approximately 12 mm from 3 , about 11mm 3 Approximately 13 mm 3 , approximately 12 mm 3 Approximately 14 mm 3 , about 13mm 3 Approximately 15 mm from 3 , approximately 14mm 3 Approximately 17.5 mm 3 , about 15mm 3 Approximately 20 mm from 3 , about 17.5mm 3 Approximately 22.5 mm 3 , about 20mm3 Approximately 25 mm from 3 , about 22.5mm 3 Approximately 30 mm from 3 , about 25mm 3 Approximately 35 mm from 3 , about 30mm 3 Approximately 40 mm from 3 , about 35mm 3 Approximately 45 mm from 3 , approximately 40 mm 3 Approximately 50 mm from 3 , about 45mm 3 Approximately 60 mm from 3 , approximately 50 mm 3 Approximately 70 mm from 3 , about 60mm 3 Approximately 80 mm from 3 , about 70mm 3 Approximately 90 mm from 3 , about 80mm 3 Approximately 100 mm from 3 , about 90mm 3 Approximately 250 mm from 3 , approximately 100 mm 3 Approximately 500 mm from 3 , about 250mm 3 Approximately 750 mm from 3 , approximately 500 mm 3 Approximately 1,000 mm from 3 , about 750mm 3 Approximately 2,500 mm from 3 , approximately 1,000 mm 3 Approximately 5,000 mm from 3 , or approximately 2,500 mm 3 Approximately 7,500 mm from 3 The volume can range from 0.01 to 0.1.

[0080] In an embodiment, the nozzle 1100 has a maximum lateral dimension D of the base 1134. B Smaller maximum horizontal dimension D N , which can aid in attaching the nozzle 1100 to the base 1134 using a swage or by using a recess defined by the base 1134. However, in such an embodiment, the smaller maximum lateral dimension D of the nozzle 1100 can be accommodated. Nlimits the volume that the nozzle 1100 can exhibit. In other words, the smaller maximum lateral dimension D N This can reduce the effects of high thermal conductivity of nozzle 1100 when nozzle 1100 is formed from PCD or PcBN. In embodiments, the nozzles disclosed herein can exhibit a maximum lateral dimension equal to or greater than the maximum lateral dimension of the base to which the nozzle is attached. In such embodiments, a nozzle exhibiting a maximum lateral dimension equal to or greater than the maximum lateral dimension of the base to which the nozzle is attached allows for increased nozzle volume. For example, FIG. 12 is a schematic cross-sectional view of a nozzle assembly 1232 having a nozzle 1200 attached to a base 1234, according to an embodiment, where the maximum lateral dimension D N is the maximum horizontal dimension D of the base 1234 B Except as otherwise disclosed herein, one or more features of nozzle 1200 or base 1234 may be equal to or substantially similar to one or more features of any of the nozzles and bases disclosed herein, respectively.

[0081] Maximum horizontal dimension D of nozzle 1200 N may inhibit or complicate attachment of the nozzle to the base 1234 utilizing certain attachment techniques (e.g., swaging) and / or using recesses. Instead, in embodiments, the nozzle 1200 may be brazed, soldered, adhesively attached, or otherwise attached to the base 1234 using any suitable technique. In embodiments, the nozzle 1200 may have a protrusion extending from its bottom surface configured to be disposed within a recess defined by the base 1234. Examples of protrusions extending from the bottom surface of a PCD body are disclosed in U.S. Provisional Application No. 63 / 154,277, filed February 26, 2021, the disclosure of which is incorporated herein by reference in its entirety.

[0082] Nozzle 1200 can exhibit any of the volumes discussed above in connection with nozzle 1100 shown in Figure 11. However, nozzle 1200 may have a volume of approximately 150 mm 3 Above, about 200mm 3 Above, about 300mm 3 Above, about 400mm 3 Above, about 500mm 3 or more, about 750mm 3 More than 1cm 3 Approximately 1.25cm or more 3 Approximately 1.5cm or more 3 Approximately 1.75cm or more 3 More than 2cm 3 Approximately 2.25cm or more 3 Approximately 2.5cm or more 3 Over, about 3cm 3 Over, about 4cm 3 Over, about 5cm 3 More than or about 100 mm 3 Approximately 200 mm from 3 , about 150mm 3 Approximately 300 mm from 3 , about 200mm 3 Approximately 400 mm from 3 , about 300mm 3 Approximately 500 mm from 3 , approximately 400 mm 3 Approximately 750 mm from 3 , approximately 500 mm 3 Approximately 1 cm from 3 , about 750mm 3 Approximately 1.25 cm 3 , about 1cm 3 Approximately 1.5 cm 3 , about 1.25cm 3 Approximately 1.75 cm 3 , about 1.5cm 3 Approximately 2 cm from 3 , about 1.75cm 3 Approximately 2.5 cm from 3 , about 2 cm 3 Approximately 3 cm from 3 , about 2.5cm 3 Approximately 4 cm from 3 , or about 3 cm 3 Approximately 5 cm from 3Note that the volume can also be in the range of

[0083] In some embodiments, the nozzles disclosed herein can form the entire nozzle assembly. For example, FIG. 13 is a schematic cross-sectional view of a nozzle assembly 1332 having a nozzle 1300 but no base, according to an embodiment. Because the nozzle 1300 forms the entire (or a large portion or substantially the entire) nozzle assembly 1332, the thermal conductivity of the nozzle 1300 can control the heating of the printing material. In such a configuration, the nozzle 1300 can include, but is not limited to, one or more superhard materials. In one embodiment, if the nozzle 1300 is formed from PCD or PcBN, the high thermal conductivity of such materials can cause at least a portion of the nozzle 1300 to heat to a substantially equal temperature (e.g., any temperature gradient within the nozzle 1300 can 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 have manufacturing size limitations. Thus, the volume and dimensions of nozzle 1300 may be limited by the manufacturing size limitations of the superhard material. Accordingly, in some embodiments, nozzle 1300 may be formed by brazing, metallurgically bonding, or otherwise attaching multiple superhard bodies (e.g., PCD and / or PcBN bodies) together to form nozzle 1300, thereby allowing nozzle 1300 to exhibit at least one of a volume or dimension greater than the manufacturing limitations of the particular superhard material.

[0084] As discussed above, any of the nozzles disclosed herein may be formed from PCD. FIG. 14 is a schematic diagram of an example method for fabricating a nozzle 1400 from PCD, according to an embodiment. Note that the nozzle 1400 may be any of the nozzles disclosed herein. Referring to FIG. 14 , a mass of diamond particles 1460 is 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 submicron. The average particle size of the diamond particles 1460 may be selected to minimize volume reduction of the nozzle formed therefrom. For example, it has been found that printing material flowing through the nozzle conduits can cause some of the diamond abrasive grains to become dislodged, thereby causing a volume loss (i.e., wear) of the nozzle. To minimize volume loss, the diamond grains 1460 can be selected to have an average grain size of less than 40 μm, so that the dislodgment of one or a few diamond abrasive grains has a negligible effect on the nozzle volume. However, it should be noted that reducing the average grain size of the diamond grains 1460 can further limit volume loss, and thus the diamond grains 1460 can be selected to have an average grain size that is significantly less than 40 μm, such as less than 20 μm or less than 10 μm.

[0085] In an embodiment, the diamond particles 1460 can include a relatively large size and at least one relatively small size. As used herein, "relatively large" and "relatively small" refer (in any suitable manner) to particle sizes that differ by at least a factor of two (e.g., 30 μm and 15 μm). According to various embodiments, the diamond particles 1460 can include a portion exhibiting a relatively large size (e.g., 30 μm, 20 μm, 15 μm, 12 μm, 10 μm, 8 μm) and another portion exhibiting at least one relatively small size (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 diamond particles 1460 can include a portion exhibiting a relatively large size between about 10 μm and about 40 μm and another portion exhibiting a relatively small size between about 1 μm and about 4 μm. In some embodiments, the mass of diamond particles 1460 may include, without limitation, three or more different sizes (e.g., one relatively large size and two or more relatively small sizes). It is noted that the as-sintered diamond abrasive grain size may differ from the average particle size of the mass of diamond particles before sintering due to a variety of different physical processes such as grain growth, diamond particle fracturing, due to carbon provided from another carbon source (e.g., dissolved carbon in a metal solvent catalyst), or a combination of the above.

[0086] A mass of diamond particles 1460 is positioned adjacent to an interface 1462 of a substrate 1464 to form an assembly 1466. The substrate 1464 may comprise a cemented carbide, such as, but not limited to, tungsten carbide, titanium carbide, chromium carbide, niobium carbide, tantalum carbide, vanadium carbide, or combinations thereof, cemented with iron, nickel, cobalt, or alloys thereof. For example, in one embodiment, the substrate 1464 comprises cobalt-cemented tungsten carbide. The substrate 1464 may have, but is not limited to, a generally cylindrical configuration or another 1462 configuration. While FIG. 14 shows the interface 1462 of the substrate 1464 as being substantially flat, the interface 1462 may also exhibit a selected non-flat topography, such as a grooved interface, a peaked interface, or other non-flat interface.

[0087] The assembly 1466 further comprises a catalyst configured to sinter the mass of diamond particles 1460. The catalyst may be provided in a specific form mixed with the mass of diamond particles 1460, as a thin foil or plate disposed adjacent to the mass of diamond particles 1460, provided from the substrate 1464 (e.g., the substrate 1464 is a cemented carbide substrate that includes a metal solvent catalyst), or a combination thereof. In an embodiment, the catalyst comprises a metal solvent catalyst (e.g., iron, nickel, cobalt, or alloys thereof). In embodiments, the catalyst comprises at least one non-metallic catalyst selected from one or more of alkali metal carbonates (e.g., one or more carbonates of Li, Na, and K), one or more alkaline earth metal carbonates (e.g., one or more carbonates of Be, Mg, Ca, Sr, and Ba), sulfates (e.g., one or more sulfates of Be, Mg, Ca, Sr, and Ba), hydroxides (e.g., one or more hydroxides of Be, Mg, Ca, Sr, and Ba), elemental phosphorus and / or derivatives thereof, chlorides (e.g., one or more chlorides of Li, Na, and K), elemental sulfur and / or derivatives thereof, polycyclic aromatic hydrocarbons (e.g., naphthalene, anthracene, pentacene, perylene, coronene, or combinations thereof) and / or derivatives thereof, chlorinated hydrocarbons and / or derivatives thereof, semiconductor materials (e.g., germanium or geranium alloys), and combinations of the above. In an illustrative example, the catalyst includes one or more metal solvent catalysts and one or more non-metal catalysts.

[0088] To efficiently sinter the mass of diamond particles 1460, the assembly 1466 may be enclosed in a pressure-transmitting medium, such as a heat-resistant metal can, a graphite structure, pyrophyllite, and / or other suitable pressure-transmitting structure to form a cell assembly. Examples of suitable gasket materials and cell structures for use in manufacturing PCD are disclosed in U.S. Patent Nos. 6,338,754 and 8,236,074, each of which is incorporated herein by reference in its entirety. Another example of a suitable pressure-transmitting material is pyrophyllite, available from Wonderstone Ltd. of South Africa.

[0089] The cell assembly 1466 containing the pressure transmission medium and the mass of diamond grains 1460 therein is subjected to an HPHT process using an ultra-high pressure press at a temperature of at least about 1000°C (e.g., about 1100°C to about 2200°C, or about 1200°C to about 1450°C) and at a pressure within the pressure transmission medium of at least about 5 GPa (e.g., 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 time sufficient to sinter the diamond grains 1460 together in the presence of a catalyst and to form a PCD table 1468 including bonded diamond grains defining interstitial regions occupied by the catalyst. The HPHT process can form a PCD compact 1470 having a PCD table 1468 bonded to the substrate during the HPHT process, and the catalyst can liquefy and, if disposed outside the diamond grains 1460, can infiltrate the clusters of diamond grains 1460. The catalyst promotes growth between adjacent clusters of diamond grains 1460, thereby forming a PCD table 1468 comprised of a cluster of bonded diamond grains with the infiltrated catalyst interstitially disposed between the bonded diamond grains. For example, if the substrate 1464 is a cobalt-bonded tungsten carbide substrate, cobalt from the substrate 1464 can liquefy and infiltrate the clusters of diamond grains 1460, catalyzing the formation of the PCD table 1468.

[0090] The pressure values ​​employed in the HPHT process disclosed herein refer to the pressure in the pressure-transmitting medium at room temperature (e.g., about 25°C) upon application of pressure using an ultra-high pressure press, without applying pressure to the exterior portion of the cell assembly 1466. The actual pressure in the pressure-transmitting medium at the sintering temperature may be slightly higher. The ultra-high pressure press may be calibrated at room temperature by embedding at least one calibration material, such as PbTe, thallium, barium, or bismuth, that changes structure at a known pressure within the pressure-transmitting medium. Optionally, a change in resistance across the at least one calibration material due to its phase change may be measured. For example, PbTe exhibits a phase change at about 6.0 GPa at room temperature, and bismuth exhibits a phase change at about 7.7 GPa at room temperature. Examples of suitable pressure calibration techniques are disclosed in G. Rousse, S. Klotz, A.M. Saitta, J. Rodriguez-Carvajal, M.I. McMahon, B. Couzine, and M. Mezouar, "Structure of the Intermediate Phase of PbTe at High Pressure," Physical Review B: Condensed Matter and Materials Physics, 71, 224116 (2005) (Non-Patent Document 1), and D.L. Decker, W.A. Bassett, L. Merrill, H.T. Hall, and J.D. Brannett, "High-Pressure Calibration: A Critical Review," J.Phys.Chem.Ref.Data, 1, 3 (1972) (Non-Patent Document 2).

[0091] In other embodiments, the PCD table 1468 according to the embodiment may be separately formed using an HPHT sintering process and then bonded to the interface 1462 of the substrate 1464 by, but not limited to, brazing, using a separate HPHT bonding process, or any other suitable joining technique. In another embodiment, the substrate 1464 may be formed by depositing a binderless carbide (e.g., tungsten carbide) via chemical vapor deposition on the separately formed PCD table 1468.

[0092] In any of the embodiments disclosed herein, substantially all or a selected portion of the catalyst (e.g., metal solvent catalyst) can be removed (e.g., via leaching) from the PCD table 1468. In embodiments, the metal solvent catalyst in the PCD table 1468 can be removed from at least one exterior working surface (e.g., the working surface and / or sidewall working surface of the PCD table 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 table 1468 in the PCD compact 1470 from the working surface to a selected depth. Leaching the catalyst from the PCD table 1468 can improve the thermal stability of the nozzle 1400 formed from the PCD table 1468. For example, leaching the catalyst from the PCD table 1468 may allow the PCD table to be brazed to a base and / or may allow the PCD table to be heated to temperatures of about or above 700° C. without substantial thermal degradation. In some embodiments, the catalyst may not be leached from the PCD table 1468. In some embodiments, the catalyst may be leached from only a portion of the PCD table, thereby improving the thermal stability of the nozzle 1400 formed from the PCD table.

[0093] In another embodiment, the PCD table 1468 can be fabricated according to any of the disclosed embodiments in a first HPHT process, subjected to leaching to remove substantially all of the metal solvent catalyst from the interstitial regions between the bonded diamond abrasive grains, and then bonded to a substrate in a second HPHT process. In the second HPHT process, an infiltrant, such as from a bonded carbide substrate, can infiltrate into the interstitial regions where the metal solvent catalyst has been removed. For example, the infiltrant can be cobalt flowing from a cobalt-bonded tungsten carbide substrate. In one embodiment, the first and / or second HPHT processes can be performed at a pressure of at least about 7.5 GPa. In one embodiment, the infiltrant can be leached from the infiltrated PCD table 1468 using a second acid leaching process performed after the second HPHT process.

[0094] In an embodiment, the PCD table 1468 may be a binderless PCD table. The binderless PCD table may be formed by pressing a block of diamond grain with or without additives such as catalysts. The diamond grain is pressed without any metal solvent catalyst present. For example, the block of diamond grain may not be disposed on a cobalt-bonded tungsten carbide substrate. The binderless PCD table may be pressed using any of the pressures and temperatures disclosed herein.

[0095] In embodiments, as shown, the substrate 1464 may be removed or otherwise detached from the PCD table 1468. For example, the substrate 1464 may be removed from the PCD table 1468 by grinding the substrate 1464 or dissolving the substrate 1464 in acid. In embodiments not shown, at least a portion of the substrate 1464 may not be removed or otherwise detached from the PCD table 1468. In such embodiments, the substrate 1464 may form a portion of a nozzle formed from the PCD table 1468.

[0096] Portions of the PCD table 1468 and optional substrate 1464 may be removed to form one or more nozzles 1400. For example, portions of the PCD table 1468 and optional substrate 1464 may 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 more than 20 nozzles 1400. The number of nozzles 1400 formed from the PCD table 1468 and optional substrate 1464 may be determined based on the size (e.g., maximum lateral dimension, thickness, and volume) of the PCD table 1468, the shape of the PCD table 1468, whether the substrate 1464 forms part of the nozzle 1400, the size of the nozzle 1400, and the shape of the nozzle 1400. The nozzle 1400 formed from the PCD table 1468 and optional substrate 1464 may have, without limitation, one or more features that are equal to or substantially similar to any one or more features of the nozzles disclosed herein.

[0097] In embodiments, these portions of the PCD table 1468 and optional substrate 1464 may be ablated using a laser. In such embodiments, a laser may emit multiple laser pulses toward one or more surfaces of the PCD table 1468 and optional substrate 1464. The laser pulses may be selected to ablate the PCD table 1468 in one or more layers. This laser ablation process may accomplish at least one of the following: forming multiple nozzles 1400 from the PCD table 1468 (e.g., simultaneously or substantially simultaneously), forming exterior structures (e.g., top, bottom, side, etc.), forming interior structures (e.g., conduits) of the nozzles 1400, or polishing the surface of the nozzles 1400. Examples of laser processing (lasing) methods that may be used to ablate portions of the PCD table 1468 are disclosed in U.S. Patent Application No. 16 / 084,469, filed January 10, 2018, the disclosure of which is incorporated herein by reference in its entirety.

[0098] In an embodiment, these portions of the PCD table 1468 and optional substrate 1464 may be removed using one or more of grinding, lapping, electrical discharge machining (e.g., wire electrical discharge machining), or any other machining technique. Unlike laser processing, some machining techniques, such as grinding, lapping, and electrical discharge machining, may exhibit high wear due to the hardness of diamond, may be unable to form all of the nozzle 1400 together (e.g., in a single process), may be unable to form both the exterior and interior structures of the nozzle 1400, or may be unable to polish the surface of the nozzle 1400. In an embodiment, these portions of the PCD table 1468 and optional substrate 1464 may be removed using laser processing and one or more of grinding, lapping, electrical discharge machining, or any other machining technique.

[0099] As discussed above, the nozzles disclosed herein can be at least partially formed from PcBN instead of or in addition to PCD. More generally, the nozzles disclosed herein can include, but are not limited to, one or more superhard materials (e.g., any material having a hardness greater than that of PCD, PCBN, silicon carbide, or tungsten carbide). For example, the nozzles may be at least partially formed from PcBN due to the hardness and thermal conductivity of PcBN, which are comparable to those of PCD. Nozzles formed from PcBN can reduce nozzle wear, extend nozzle life, enable use of the nozzle with abrasive printing materials, and improve the consistency of printed materials formed using the nozzle. PcBN can exhibit higher thermal stability than PCD, allowing nozzles formed from PcBN to be heated to higher temperatures than nozzles comprising PCD. For example, PCD can exhibit thermal degradation when heated to temperatures above 700°C if the PCD contains a metal solvent catalyst, whereas PcBN can be heated to temperatures above 700°C without substantial degradation.

[0100] In an embodiment, the entire nozzle may be formed from PcBN. Forming the entire nozzle from PcBN may make the nozzle easier to manufacture because there is no need to attach the PcBN to another material and improve the nozzle's wear characteristics. In another embodiment, only a portion of the nozzle is formed from PcBN. Forming only a portion of the nozzle from PcBN may make the nozzle easier to mold and machine because other materials in the nozzle may have a lower hardness than PcBN. However, forming only a portion of the nozzle from PcBN may require bonding the PcBN to another material, which increases the complexity of nozzle manufacture. Furthermore, the fact that a portion of the nozzle is formed from a material that is less hard than PcBN may increase wear on the portion of the nozzle formed from this lower hardness material, thereby shortening the nozzle's lifespan. In an example, where only a portion of the nozzle comprises PcBN, at least a portion of the conduit surface 110, and particularly this portion of the conduit surface 110 and any other interior surfaces of the nozzle adjacent the orifice 114, may be defined by PcBN. In such an example, the PcBN may reduce wear on the orifice 114 compared to a lower hardness material, thereby maintaining consistency in the printing material dispensed from the nozzle compared to forming the entire nozzle from a lower hardness material.

[0101] PcBN can be formed by heating boron nitride at any of the same temperatures and pressures discussed above, such as temperatures from about 1000°C to about 1450°C and pressures from about 5 GPa to about 14 GPa. Catalysts for PcBN include, for example, alkali metals, antimony, lead, tin, lithium, magnesium, and nitrides. After forming the PcBN, one or more nozzles can be formed therefrom using the same techniques as those discussed above in connection with PCD. For example, nozzles can be formed by laser processing, grinding, lapping, electrical discharge machining, or any other suitable machining technique.

[0102] In some examples, one or more nozzles can be fabricated via a process that results in a nozzle having a selected orifice geometry. For example, a nozzle can have an exit orifice that exhibits a selected ratio between a height extending in the direction of fluid flow (e.g., a fluid path through the nozzle) and a width (e.g., a diameter) extending transversely (e.g., substantially perpendicular) to the height and / or fluid path. The processes discussed herein can enable a selected height / diameter ratio for an orifice disposed at the exit of the nozzle. For example, such methods of machining a material (e.g., an ultrahard material such as PCD) can enable fabrication of a nozzle 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 examples, such orifice geometries can facilitate reducing back pressure within the nozzle, which can enable the ability to increase printing speeds when the nozzle is implemented in a printing application.

[0103] Figures 15 and 16 show the interior portion of a nozzle 1500 defined within a volume or mass of material (e.g., a PCD table 1504 or disk) via one or more machining processes (e.g., laser ablation). For clarity, the nozzle 1500 in Figure 15 is shown as already having some external features formed within the PCD table 1504, but it should be understood that the PCD table 1504 can be a volume of material that has only a portion of one or more internal features formed within it.

[0104] Similar to the above, in some embodiments, the nozzle 1500 may be formed along with multiple other nozzles from an ultra-hard material (e.g., PCD). Also as discussed above, in some embodiments, the interior portion of the nozzle 1500 (e.g., the conduit 1502) may be defined while the nozzle 1500 is part of an overall PCD table (e.g., PCD table 1468 shown in FIG. 14). The exterior portion of the nozzle 1500 (e.g., the outer section 1520) may be formed when the individual nozzle 1500 is singularized (e.g., separated from the overall PCD table) from the PCD table. In additional embodiments, the nozzle 1500 may be formed separately in one or more machining processes and / or the exterior portion may be defined before one or more portions of the conduit 1502 are defined.

[0105] 15, the PCD table 1504 can be mounted in a fixture 1506 (e.g., a machined structure) that uses a clamping force to maintain the position of the PCD table 1504. The fixture 1506 can position the PCD table 1504 so that a bottom or proximal side 1510 is exposed, allowing material to be removed from the proximal side 1510. A first portion 1508 of the conduit 1502 (e.g., a proximal or inlet portion formed as a blind hole having a substantially conical shape) can be machined (e.g., laser machined) into the PCD table 1504. Other geometric features at or near the bottom or proximal side 1510 of the nozzle 1500 can be formed in the same machining process as the proximal side 1510 of the nozzle 1500.

[0106] 16, the fixture 1506 may then be rotated (e.g., rotated 180 degrees, flipped over, etc.) and remounted or placed on the machining device (e.g., exposing the distal side 1511 of the nozzle 1500 for machining). In some embodiments, a support material and / or bottom plate 1512 may be placed over the first portion 1508 of the conduit 1502 to support the PCD table 1504 during subsequent machining.

[0107] A second portion 1514 of the conduit 1502 may be machined (e.g., laser machined) into the nozzle 1500. For example, the second portion 1514 may define an orifice 1515 that comprises a distal or outlet portion of the conduit 1502. The second portion 1514 may be formed to connect with the first portion 1508 to create an entire throughbore of the conduit 1502 that provides a fluid outlet at the orifice 1515. The throughbore of the conduit 1502 may define a fluid pathway 1518 through the nozzle 1500, which may extend substantially axially of the nozzle 1500.

[0108] As discussed below, the exit orifice 1515 can be a substantially straight orifice (e.g., having a substantially constant diameter) or can be tapered. For example, the second portion 1514 or orifice 1515 can have a substantially conical shape that is opposite to the conical shape of the first portion 1508, where the diameter of the orifice 1515 can increase as it approaches the distal side 1511 of the nozzle 1500. In embodiments where the orifice 1515 is tapered, the inner surface of the nozzle 1500 that forms the orifice 1515 can have a taper (e.g., an angle relative to the central axis of the nozzle 1500) of 1 to 45 degrees, 5 to 15 degrees, less than 30 degrees, 0.1 to 30 degrees, etc.

[0109] In some embodiments, as depicted, the interface between the orifice 1515 and the first portion 1508 can comprise a reduced diameter section to define a neck portion of the nozzle 1500 .

[0110] In some embodiments, the distal-most portion of the orifice 1515 can include a chamfered or rounded portion 1516 at the distal-most portion of the conduit 1502. For example, all or a portion (e.g., the distal-most part) of the orifice 1515 can include the chamfered portion 1516.

[0111] In some embodiments, during the same setup (e.g., with the same orientation of the fixture 1506 shown in FIG. 16 ), the outer portion 1520 of the nozzle 1500 (e.g., the outer tapered portion of the tip of the nozzle 1500) may be defined and the nozzle 1500 may be separated from the overall PCD table 1504. Such a configuration allows the second portion 1514 and orifice 1515 to be formed in conjunction with the process of separating the nozzle 1500 from the PCD table 1504, with any other nozzles 1500 being formed substantially simultaneously (e.g., via the same processing steps as the initial nozzle 1500).

[0112] In some embodiments, a manufacturing method in which the conduit 1502 is formed in at least two separate processes can help maintain concentricity of the outlet of the orifice 1515 (e.g., second portion 1514) relative to one or more portions of the diameter of the nozzle 1500 (e.g., the outer diameter of the tip of the nozzle 1500 and / or the outer tapered portion of the outer portion 1520 of the nozzle 1500).

[0113] 17-19 show examples of nozzles 1700, 1800, 1900 that may be formed by a process that includes machining steps performed on multiple sides of a material. For example, nozzles 1700, 1800, 1900 may be formed by a process such as the process discussed above with reference to FIGS. 15 and 16. As shown in FIGS. 17-19, nozzles 1700, 1800, 1900 may each exhibit an orifice 1714, 1814, 1914 at the outlet of nozzle 1700, 1800, 1900, respectively, that has a relatively small height (along a longitudinal axis, centerline, or fluid flow through nozzle 1700, 1800, 1900) compared to its width (e.g., diameter in a direction transverse to the height).

[0114] In some embodiments, the conduits 1702, 1802, 1902 of the nozzles 1700, 1800, 1900 can be generally conical in shape and can include one or more inner surface sections that are disposed at an angle relative to one another, as discussed in detail above.

[0115] 17, the nozzle 1700 can include an orifice 1714 having a height / diameter ratio that is less than 1.2 (e.g., less than 0.4, about 0.31). For example, the orifice 1714 can have a height of about 0.127 mm (0.005 inches) and a diameter of 0.406 mm (0.016 inches). In some embodiments, the orifice 1714 can be tapered (e.g., about a 12 degree taper) and can include a chamfered portion 1716.

[0116] 18, the nozzle 1800 can include an orifice 1814 having a height / diameter ratio that is less than 1.2 (e.g., less than 0.25, about 0.2). For example, the conduit 1802 can have a height of about 0.127 mm (0.005 inches) and a diameter of 0.61 mm (0.024 inches). In some embodiments, the orifice 1814 can be tapered (e.g., about a 5 degree taper) and can include a chamfered portion 1816.

[0117] 19, the nozzle 1900 can include an orifice 1914 having a height / diameter ratio that is 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-walled orifice and can include a chamfered portion 1916.

[0118] While various aspects and embodiments are disclosed herein, other aspects and embodiments are contemplated. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting.

[0119] Terms of degree (e.g., "about," "substantially," "generally," "about," etc.) indicate insignificant amounts of structural or functional variation. Illustratively, when a quantitative term includes a term of degree, the term of degree is interpreted to mean ±10%, ±5%, +2%, +1%, or even +0% of the quantitative term. Illustratively, when a term of degree is used to modify a shape, the term of degree indicates that the shape modified by the term of degree has the appearance of the disclosed shape. For example, the term of degree may be used to indicate that a shape may have curved corners instead of sharp angles, may have curved edges instead of straight edges, may have one or more protrusions extending therefrom, is elongated, is equivalent to the disclosed shape, etc.

Claims

1. 1. A method of forming a nozzle for use in a three dimensional printing process, comprising: Fixturing the material in a machining fixture; forming a hole in the material at a first side thereof to define an at least partially conical inner conduit extending at least partially through the material; forming a through hole in the material on a second side of the material to define an exit orifice for the nozzle, the exit orifice connecting with the at least partially conical inner conduit to define a fluid path through the nozzle; defining the exit orifice to have a height extending along the fluid path of the nozzle and a width extending transversely to the height of the exit orifice, wherein the ratio of the height to the width is substantially equal to or less than 1.2; forming an exterior portion of the nozzle to detach the nozzle from the remainder of the material; A method comprising:

2. The method of claim 1 , further comprising, after forming the holes in the first side of the material, rotating the material 180 degrees to expose the second side.

3. The method of claim 2 further comprising defining the exit orifice such that the ratio of the height to the width is less than 0.

5.

4. The method of claim 3 further comprising defining the exit orifice such that the ratio of the height to the width is less than 0.

35.

5. The method of claim 1 , further comprising defining a chamfer at a distal-most portion of the exit orifice.

6. The method of claim 1 , further comprising forming the orifice to present a tapered inner surface having a taper of between 0.1 and 30 degrees.

7. The method of claim 1 , further comprising forming a plurality of nozzles from at least a portion of the remainder of the material substantially simultaneously with the nozzle.

8. 7. The method of claim 1, wherein the step of clamping the material in the machining fixture comprises clamping a polycrystalline diamond table in the machining fixture.

9. 7. The method of claim 1, wherein forming holes in the material comprises forming blind holes in the material.

10. 1. A method of forming a nozzle for use in a three dimensional printing process, comprising: forming a hole in the material at a first side thereof to define an at least partially conical inner conduit extending at least partially through the material; reorienting the material so that a second side opposite the first side is exposed; forming a through hole in the material at the second side of the material to define an exit orifice for the nozzle, the exit orifice connecting with the at least partially conical inner conduit to define a fluid path through the nozzle; removing the nozzle from the remainder of the material; A method comprising:

11. 11. The method of claim 10, further comprising shaping the exit orifice to have a height extending along the fluid path of the nozzle and a width extending transversely to the height of the exit orifice, wherein the ratio of the height to the width is substantially equal to or less than 1.

2.

12. The method of claim 10 , further comprising continuously exposing the second side of the material while forming the outer portion of the nozzle.

13. 13. The method of any one of claims 10 to 12, further comprising forming additional nozzles from the material substantially simultaneously with the nozzles.

14. 13. The method of any one of claims 10 to 12, further comprising forming the hole only partially through the material to define a blind hole.

15. 1. A nozzle for three dimensional printing, said nozzle comprising: at least one proximal surface defining an inlet of the nozzle; at least one distal surface opposite the at least one proximal surface, the distal surface defining an outlet of the nozzle; at least one outer surface extending from the at least one proximal surface to the at least one distal surface; at least one conduit surface extending from the at least one proximal surface to the at least one distal surface, the at least one conduit surface defining a fluid flow conduit through the nozzle; Including, an interface between the at least one conduit surface and the at least one distal surface defines an exit orifice of the nozzle; 10. The nozzle of claim 1, wherein the outlet orifice exhibits a height extending in a direction along the fluid flow conduit and a width extending transversely to the height of the outlet orifice, the ratio of the height to the width being substantially 1.2 or less.

16. 16. The nozzle of claim 15, wherein the ratio of the height to the width is substantially equal to or less than 0.

75.

17. 17. The nozzle of claim 16, wherein the ratio of the height to the width is substantially equal to or less than 0.

5.

18. 18. The nozzle of claim 17, wherein the ratio of the height to the width is substantially equal to or less than 0.

35.

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

20. 19. A nozzle according to any one of claims 15 to 18, wherein the orifice presents a tapered inner surface having a taper of between 0.1 and 30 degrees.

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