3D Printing Nozzle Conduit Geometry for Abrasive Material Wear
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Solution Overview
Problem
Conventional nozzles and nozzle assemblies in 3D printing suffer from material leakage and excessive wear due to unsatisfactory performance with abrasive printing materials.
Innovation Solution
The development of nozzles and nozzle assemblies featuring a non-vertical conduit surface made from superhard materials like polycrystalline diamond (PCD) or polycrystalline cubic boron nitride (PcBN), which include non-vertical conduit surfaces and chamfers to reduce wear, prevent clogging, and facilitate smooth material flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional nozzles are used with abrasive printing materials, then the nozzle structure is simple and easy to manufacture, but the nozzle experiences excessive wear and material leakage
Solution Approach 1:
The nozzle is constructed using composite materials, specifically a superhard material (such as diamond-like carbon or cubic boron nitride) applied as a coating or integrated layer on the conduit surface. This composite structure provides exceptional wear resistance against abrasive printing materials while maintaining the structural integrity and manufacturability of the base nozzle material, thereby resolving the contradiction between durability and ease of manufacture
Solution Approach 2:
The superhard material is applied selectively to specific regions of the nozzle that experience the most wear, such as the conduit surface and orifice area. This localized application of enhanced material properties provides maximum wear protection where needed most while keeping the rest of the nozzle structure simple and easy to manufacture, resolving the contradiction between durability and manufacturing complexity
2Productivity
If conventional vertical conduit surfaces are used, then the nozzle structure is simple, but material flow is obstructed and clogging occurs
Solution Approach 1:
The conduit surface is designed with curved or non-vertical geometry instead of straight vertical walls. This curvature creates a more favorable flow path for the printing material, reducing turbulence and preventing material from adhering to the walls, thereby improving material flow smoothness and preventing clogging while adding moderate geometric complexity
3Strength
If no superhard material coating is applied, then the nozzle is easier to manufacture, but wear resistance is insufficient with abrasive materials
Solution Approach 1:
A superhard material coating (such as diamond-like carbon or cubic boron nitride) is applied to the nozzle conduit surface through deposition processes. This coating provides exceptional wear resistance against abrasive printing materials while the base nozzle structure remains relatively simple to manufacture, resolving the contradiction between wear resistance and ease of manufacture by combining materials with complementary properties
Data Source
AI summary
Embodiments are directed to nozzles for three-dimensional printing and related nozzle assemblies and methods. An example nozzle includes at least one top surface, at least one bottom surface, and at least one lateral surface extending from or near the top surface to or near the bottom surface. The nozzle includes 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 an embodiment, at least a portion of the conduit surface proximate to the top surface is non-vertical (e.g., defines a non-cylindrical or non-rectangular shape). The non-vertical conduit surface may be positioned such that it is not parallel to a central axis of the nozzle extending from the top surface to the bottom surface.