Nozzle system with monolithic nozzle head for fused filament fabrication additive manufacturing and method of manufacturing same

1. A nozzle system for use in an additive manufacturing system for fabricating an object, the nozzle system comprising:

a heat sink having a heat sink proximate end and a heat sink distal end; and

a nozzle head having a nozzle head proximate end and a nozzle head distal end, the nozzle head comprising:

a thermal locking member positioned at the nozzle head proximate end;

a neck member; and

a nozzle member positioned at the nozzle head distal end, wherein the nozzle member is joined to the thermal locking member via the neck member;

wherein the thermal locking member is connected to the heat sink at the heat sink distal end;

wherein an outer diameter of the neck member is less than outer diameters of the thermal locking member and the nozzle member; and

wherein a combination of the thermal locking member, the neck member, and the nozzle member is monolithic.

2. The nozzle system of claim 1 , wherein the thermal locking member, neck member, and nozzle member all comprise a metal selected from the group consisting of titanium, an austenitic nickel-chromium-based super alloy, a nickel-molybdenum-chromium alloy, or a combination thereof.

3. The nozzle system of claim 1 , wherein the heat sink comprises a thermal locking bore positioned at the heat sink distal end, and wherein the thermal locking member is connected to the heat sink via the thermal locking bore.

4. The nozzle system of claim 3 , wherein the thermal locking member is connected to the heat sink via the thermal locking bore via a thermal coupling connection.

5. The nozzle system of claim 1 , wherein the nozzle head further comprises a nozzle head inner bore extending through the thermal locking member, the neck member, and the nozzle member from the nozzle head proximate end to the nozzle head distal end, and wherein the outer diameter of the neck member is slightly greater than a nominal diameter of the nozzle head inner bore.

6. The nozzle system of claim 1 , wherein the nozzle head further comprises a nozzle head inner bore extending through the thermal locking member, the neck member, and the nozzle member from the nozzle head proximate end to the nozzle head distal end, wherein the nozzle member comprises two heater cartridge bores, and wherein the nozzle head inner bore is positioned between the two heater cartridge bores.

7. The nozzle system of claim 6 , further comprising two heater cartridges, wherein each heater cartridge comprises a heating element, and wherein each heating element is connected to the nozzle member within a corresponding one of the two heater cartridge bores.

8. The nozzle system of claim 7 , wherein each heating element is connected to the nozzle member within the corresponding one of the two heater cartridge bores via a thermal coupling connection.

9. A method of manufacturing a nozzle system for use in an additive manufacturing system for fabricating an object, the method comprising:

providing a heat sink having a heat sink proximate end and a heat sink distal end;

monolithically forming a nozzle head having a nozzle head proximate end and a nozzle head distal end, the nozzle head comprising:

a thermal locking member positioned at the nozzle head proximate end;

a neck member; and

a nozzle member positioned at the nozzle head distal end, wherein the nozzle member is joined to the thermal locking member via the neck member; and

connecting the thermal locking member to the heat sink at the heat sink distal end;

wherein an outer diameter of the neck member is less than outer diameters of the thermal locking member and the nozzle member; and

wherein the step of monolithically forming the nozzle head comprises monolithically forming the thermal locking member, the neck member, and the nozzle member in combination.

10. The method of claim 9 , wherein the thermal locking member, neck member, and nozzle member all comprise a metal selected from the group consisting of titanium, an austenitic nickel-chromium-based super alloy, a nickel-molybdenum-chromium alloy or a combination thereof.

11. The method of claim 9 , wherein the heat sink comprises a thermal locking bore positioned at the heat sink distal end, and wherein connecting the thermal locking member to the heat sink at the heat sink distal end comprises connecting the thermal locking member to the heat sink via the thermal locking bore.

12. The method of claim 11 , wherein connecting the thermal locking member to the heat sink via the thermal locking bore is performed via thermal coupling.

13. The method of claim 9 , wherein the nozzle head further comprises a nozzle head inner bore extending through the thermal locking member, the neck member, and the nozzle member from the nozzle head proximate end to the nozzle head distal end, and wherein the outer diameter of the neck member is slightly greater than a nominal diameter of the nozzle head inner bore.

14. The method of claim 9 , wherein the nozzle head further comprises a nozzle head inner bore extending through the thermal locking member, the neck member, and the nozzle member from the nozzle head proximate end to the nozzle head distal end, wherein the nozzle member comprises two heater cartridge bores, and wherein the nozzle head inner bore is positioned between the two heater cartridge bores.

15. The method of claim 14 , further comprising providing two heater cartridges, wherein each heater cartridge comprises a heating element, and wherein the method further comprises connecting each heating element to the nozzle member within a corresponding one of the two heater cartridge bores.

16. The method of claim 15 , wherein connecting each heating element to the nozzle member within the corresponding one of the two heater cartridge bores is performed via thermal coupling.