Superhard 3D Printing Nozzles for Abrasive Wear

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional nozzles and nozzle assemblies in 3D printing suffer from material leakage and excessive wear due to unsatisfactory design, particularly when handling abrasive materials.

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), with non-vertical conduit surfaces and polished surfaces to reduce wear and prevent leakage, clogging, and improve material flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional nozzles are used for 3D printing, then material dispensing is achieved, but excessive wear and material leakage occur

Engineering Contradiction:

Improvenozzle durabilityVSAvoidnozzle service life

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

The nozzle conduit surface is modified by changing its physical-chemical parameters through plasma treatment and coating application. The surface energy, roughness, and chemical composition are altered to create a non-stick surface that prevents material adhesion and leakage while maintaining durability against abrasive materials

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The nozzle employs a composite structure combining a metallic base material with a specialized coating layer. This composite construction provides both mechanical strength from the metal substrate and wear/corrosion resistance from the coating, solving the contradiction between durability and service life

Inventive Principle:

Principle #40Composite materials

2Productivity

If conventional nozzle designs are used, then material flow is achieved, but clogging and leakage problems occur

Engineering Contradiction:

Improvematerial dispensing efficiencyVSAvoidmaterial flow consistency

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The nozzle conduit features a curved, non-linear flow path instead of straight sections. This curvature design prevents material stagnation and reduces pressure buildup that leads to clogging, while maintaining smooth material flow and consistent dispensing performance

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The invention replaces mechanical wear-resistant surfaces with a chemically engineered non-stick coating system. This substitution eliminates the need for mechanically hard surfaces that can still be compromised by abrasive materials, providing reliable material flow through chemical surface properties rather than mechanical strength

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12403486B2Nozzles, nozzle assemblies, and related methods

Publication Date: 2025.09.02 US SYNTHETIC CORP

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.