Additive Manufacturing Nozzle with Coanda Guide Surface
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Solution Overview
Problem
In additive manufacturing, material fed through a nozzle can scatter when ejected, leading to inconsistent layer formation and reduced precision in three-dimensional object creation.
Innovation Solution
A nozzle design featuring a first passage for an energy ray and a second passage for powder and fluid, where the fluid ejected from the nozzle flows along a surface and separates at an edge, allowing precise material delivery and convergence at the processing point, utilizing the Coanda effect to enhance material and gas flow precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If material is ejected from the nozzle opening, then material delivery is achieved, but material scatters and convergence precision deteriorates
Solution Approach 1:
A guide surface is introduced as an intermediary element between the nozzle opening and the material flow path. This guide surface mediates the interaction between the ejected material and the surrounding environment, directing the material flow along a controlled path to prevent scattering and ensure precise convergence at the processing point.
Solution Approach 2:
The invention utilizes fluid dynamics principles by designing the guide surface to work with the fluid carrier gas flow. The surface geometry is optimized to align with the fluid flow patterns, using pneumatic/hydraulic forces to control material deposition and prevent scattering through coordinated gas flow management.
2Device complexity
If the nozzle structure is simplified, then device complexity is reduced, but material flow control precision deteriorates
Solution Approach 1:
The nozzle structure is segmented into distinct functional zones: a material ejection region, a guide surface region, and a processing point region. This segmentation allows each zone to be optimized independently for its specific function while maintaining overall structural simplicity. The guide surface is positioned as a separate functional element that can be independently designed and manufactured.
Solution Approach 2:
The guide surface extends in a direction parallel to the nozzle axis, utilizing a dimensional approach that adds control capability without significantly increasing structural complexity. By arranging the guide surface in a specific spatial configuration (parallel to the axis and positioned at a calculated distance), the invention achieves enhanced material flow control through spatial arrangement rather than through complex multi-component structures.
3Manufacturing precision
If the guide surface is positioned closer to the nozzle opening, then material convergence is improved, but the risk of laser beam damage to the guide surface increases
Solution Approach 1:
The invention optimizes critical parameters including the guide surface position distance (calculated as L × tan θ), the guide surface inclination angle (θ between 5° and 45°), and the material flow rate to achieve the optimal balance between convergence precision and damage prevention. By carefully adjusting these parameters, the guide surface is positioned close enough to improve convergence while remaining distant enough from direct laser exposure.
Solution Approach 2:
The invention strategically positions the guide surface to utilize the fluid carrier gas flow for cooling and protection. The fluid flow that would otherwise be a separate control mechanism becomes a protective element, cooling the guide surface and preventing laser beam damage while simultaneously contributing to material convergence control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design improves the precision of material deposition, enabling higher resolution in additive manufacturing by ensuring accurate convergence of material and gas, reducing scatter and enhancing the ability to handle materials with higher melting points, while minimizing nozzle damage from the laser beam.
Implementation Method 1
The nozzle unit allows the fluid ejected from the second open end to flow along the second surface, to separate at the second edge, and to depart from the nozzle unit
Data Source
AI summary
A nozzle according to one embodiment has an inner surface and an outer surface, and is provided with a first passage through which an energy ray passes, and a second passage that is provided between the inner surface and the outer surface, and through which powder and fluid pass. The second passage includes a second open end on one end thereof in a first direction. A first surface that is one of the inner surface and the outer surface includes a first edge on one end thereof in the first direction. A second surface that is the other one of those includes a second edge on one end thereof in the first direction, and is distanced from the first edge toward the first direction. The fluid ejected from the second open end flows along the second surface, and separates at the second edge.