Superhard 3D Printing Nozzle Geometry for Wear and Clog Reduction

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional nozzles and nozzle assemblies in 3D printing suffer from issues such as material leakage and excessive wear, 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), which include non-vertical conduit surfaces and chamfers to reduce wear, prevent clogging, and facilitate material flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If conventional nozzles are used for dispensing abrasive materials, then material flow is achieved, but excessive wear occurs on the nozzle

Engineering Contradiction:

Improvenozzle service lifeVSAvoidwear from abrasive materials

Core Design Contradiction:

Duration of action of moving objectVSObject-affected harmful factors

Solution Approach 1:

The nozzle surface hardness is changed from conventional materials to superhard materials (diamond, cubic boron nitride), representing a parameter change in material properties. This resolves the contradiction by enabling the nozzle to resist abrasive wear while maintaining material flow capabilities.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The nozzle is constructed using composite or coated structures incorporating superhard materials like diamond or cubic boron nitride on the dispensing surface. This composite approach allows the nozzle to withstand abrasive materials while preserving smooth material flow through the conduit.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If conventional vertical conduit surfaces are used, then manufacturing is simplified, but material clogging occurs

Engineering Contradiction:

Improveconduit surface fabricationVSAvoidmaterial flow consistency

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The conduit surface is designed with non-vertical, curved, or tapered geometries instead of straight vertical walls. This curvature prevents material from adhering to the conduit walls and reduces clogging, while the manufacturing process (such as EDM or laser drilling) can still achieve these complex shapes efficiently.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Ease of manufacture

If conventional nozzle materials are used, then manufacturing cost is reduced, but leakage occurs

Engineering Contradiction:

Improvenozzle fabrication costVSAvoidmaterial sealing

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The surface hardness parameter of the nozzle material is dramatically increased by using superhard materials. This parameter change creates extreme surface stability and dimensional precision that prevents material leakage, while the overall nozzle structure and manufacturing processes remain cost-effective.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20260084372A1Nozzles, nozzle assemblies, and related methods

Publication Date: 2026.03.26 US SYNTHETIC CORP

AI summary

Nozzles for three-dimensional printing and related nozzle assemblies and methods may include 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.