3D Printing Nozzle Geometry With Superhard Wear Surfaces
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Solution Overview
Problem
Conventional nozzles and nozzle assemblies in 3D printing suffer from unsatisfactory material leakage and excessive wear due to the use of abrasive printing materials, leading to contamination and clogging issues.
Innovation Solution
The development of nozzles and nozzle assemblies featuring non-vertical conduit surfaces made from superhard materials like polycrystalline diamond (PCD) or polycrystalline cubic boron nitride (PcBN), which reduce wear, minimize material leakage, and prevent clogging by optimizing the conduit geometry for smoother material flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional nozzle materials are used, then manufacturing cost is low, but wear resistance is insufficient leading to excessive wear
Solution Approach 1:
The nozzle is constructed using composite materials, specifically a superhard material (such as diamond-like carbon, cubic boron nitride, or silicon carbide) applied as a coating or integrated layer on the inner conduit surface. This composite structure provides enhanced wear resistance against abrasive printing materials while the base nozzle material (such as metal or polymer) maintains manufacturability and structural integrity. The superhard material layer thickness is controlled to balance wear protection with manufacturing feasibility.
2Productivity
If conventional vertical conduit surfaces are used, then manufacturing is simple, but material flow is poor causing clogging and leakage
Solution Approach 1:
The conduit surface is designed with non-vertical, curved geometries including conical sections, tapered portions, and rounded transitions instead of straight vertical walls. These curved surfaces optimize material flow by reducing friction and preventing material adhesion to the conduit walls. The specific curvature profiles (such as 45-degree angles, gradual tapers, or rounded corners) are engineered to match the rheological properties of the printing material, ensuring smooth flow and preventing clogging while maintaining manufacturing feasibility through techniques like injection molding or CNC machining.
3Reliability
If conventional nozzle materials are used, then initial cost is low, but durability is poor due to contamination and clogging
Solution Approach 1:
The nozzle incorporates superhard materials (diamond-like carbon, cubic boron nitride, or silicon carbide) as coating layers or integrated components on the inner conduit surface. These materials provide exceptional resistance to contamination and clogging by preventing abrasive printing materials from adhering to or eroding the conduit walls. The composite structure maintains manufacturing feasibility by applying these superhard materials through techniques such as chemical vapor deposition (CVD), physical vapor deposition (PVD), or as wear-resistant liners, balancing durability enhancement with manufacturing complexity.
Data Source
AI summary
Embodiments are directed to nozzles for three-dimensional printing and related assemblies and methods. An example method includes, on a first side of a material, forming a hole into the material to define an at least partially conical inner conduit extending at least partially through the material, and, on a second side of the material, forming a through-hole into 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.