Core-Shell Nozzle Design to Reduce Dead Volume in 3D Printing
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Solution Overview
Problem
Existing 3D printing technologies face challenges in achieving precise control over the extrusion of multi-layer filaments with core-shell structures due to issues like dead volume and air pockets, which affect the accuracy and resolution of the printed objects.
Innovation Solution
A core-shell nozzle design with retracted nozzle tips and corrugated surfaces is introduced, allowing for precise control over the flow rates and surface areas of materials, reducing dead volume and preventing air pockets by ensuring uniform extrusion and increased contact area between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional nozzle design is used for multi-layer filament extrusion, then the printing process can proceed, but dead volume and air pockets form reducing precision and resolution
Solution Approach 1:
The nozzle is segmented into multiple independent channels (first channel for outer shell material, second channel for core material) with separate control, allowing independent flow rate adjustment for each material layer, preventing air pockets and dead volume formation at material interfaces
Solution Approach 2:
The nozzle employs a nested channel configuration where the second channel (core material) is positioned within the first channel (outer shell material), creating a core-shell filament structure with precise concentric alignment and minimal interfacial dead volume
2Quantity of substance
If nozzle tips are extended to increase material flow, then extrusion volume increases, but dead volume increases reducing extrusion precision
Solution Approach 1:
The nozzle incorporates adjustable flow rates for each channel independently, allowing dynamic control of material extrusion quantities without being constrained by fixed nozzle geometry, enabling precise extrusion control while maintaining adequate material flow volume
Solution Approach 2:
The system changes the flow rate parameters of each channel independently to control material extrusion, allowing precise adjustment of extrusion quantities without increasing dead volume, as the channel lengths are optimized rather than simply extended
3Strength
If layer contact area is increased to improve bonding, then more complex nozzle structure is needed
Solution Approach 1:
The nozzle incorporates corrugated surfaces with curved wave patterns on the inner walls of the channels, increasing the surface area and contact area between extruded layers through a relatively simple geometric modification that enhances bonding without major structural complexity
Solution Approach 2:
The corrugated surface design creates flexible-like surface geometry that increases layer contact area, improving interlayer bonding through enhanced surface interaction while maintaining a straightforward nozzle construction
Data Source
AI summary
In one aspect, the present disclosure provides a nozzle for 3-D printing. The nozzle may include a first nozzle tip defining a first outlet, where the first nozzle tip includes a first channel extending therethrough. The nozzle may further include a second nozzle tip defining a second outlet, where the second nozzle tip includes a second channel extending therethrough, and where the first channel surrounds the second outlet. The second nozzle tip may be retracted longitudinally with respect to the first nozzle tip such that the second outlet of the second nozzle tip is located in the first channel.