Hackaday · Creativity & design

Internal Geometry Changes for FDM Nozzles

Researchers are exploring modifications to the internal geometry of FDM printer nozzles to increase filament flow rates, a key bottleneck in achieving faster print speeds.

One approach involves splitting the material path into three winding sections to theoretically enhance flowrate. These experimental nozzles were created using SLS printing and required finishing on a lathe, including drilling the nozzle hole.

The finished nozzles feature diverse internal designs, such as the triple-path configuration and various intrusions aimed at maximizing contact area.

Tests were conducted on a Prusa Core One to evaluate print quality at high flow rates. A specialized test rig was also employed to measure nozzle pressure, indicating at which flowrate performance degrades.

The 'Fuge' design showed the best results among the tested nozzles. However, a significant limitation is that these nozzles were printed using MS1, a material akin to tool steel, which is not ideal for nozzle applications.

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