NOZZLES, NOZZLE ASSEMBLIES, AND RELATED METHODS
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.
1 . A method of forming a nozzle for use in a three-dimensional printing process, the method comprising:
securing a material in a machining fixture;
on a first side of the material, forming a hole into the material to define an at least partially conical inner conduit extending at least partially through the material;
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;
defining the exit orifice to have a height extending in a direction along the fluid pathway of the nozzle and a width extending in a direction transverse to the height of the exit orifice, a ratio of the height relative to the width being substantially 1.2 or less; and
forming an exterior of the nozzle to remove the nozzle from a remaining amount of the material.
2 . The method of claim 1 , further comprising, after forming the hole on the first side of the material, rotating the material 180 degrees to expose the second side.
3 . The method of claim 2 , further comprising defining the exit orifice such that the ratio of the height relative to the width is less than 0.5.
4 . The method of claim 3 , further comprising defining the exit orifice such that the ratio of the height relative to the width is less than 0.35.
5 . The method of claim 1 , further comprising defining a chamfer on a distalmost portion of the exit orifice.
6 . The method of claim 1 , further comprising forming the exit orifice to exhibit a tapered inner surface having 0.1 to 30 degree taper.
7 . The method of claim 1 , further comprising forming a plurality of nozzles from at least a portion of the remaining amount of the material substantially concurrently with the nozzle.
8 . The method of claim 1 , wherein securing the material in the machining fixture comprises securing a polycrystalline diamond table in the machining fixture.
9 . The method of claim 1 , wherein forming the hole into the material comprises forming a blind hole into the material.
10 . The method of claim 1 , further comprising removing at least some of the material with a laser process comprising defining at least one of a stepped surface, a rastering pattern, or one or more microfeatures in the material with the laser process.
11 . A nozzle for three-dimensional printing, the nozzle comprising:
a first side opening in the nozzle defining an inlet and a first portion of an at least partially conical inner conduit; and
a second side opening in the nozzle defining a second portion of the at least partially conical inner conduit and an exit orifice, the exit orifice, the inlet, and the at least partially conical inner conduit connecting to define a fluid pathway through the nozzle, the first side opening and/or the second side opening having been formed by a laser process to remove at least some of the nozzle.
12 . The nozzle of claim 11 , wherein the nozzle comprises one or more microfeatures formed by the laser process.
13 . The nozzle of claim 12 , wherein the one or more microfeatures define one or more rostering patterns.
14 . The nozzle of claim 11 , wherein the exit orifice exhibits a height extending in a direction along the fluid pathway of the nozzle and a width extending in a direction transverse to the height of the exit orifice, a ratio of the height relative to the width being 1.2 or less.
15 . A nozzle for three-dimensional printing, the nozzle comprising:
at least one proximal surface defining an inlet of the nozzle;
at least one distal surface opposite the at least one proximal surface, the at least one distal surface defining an outlet of the nozzle;
at least one external surface extending from the at least one proximal surface to the at least one distal surface; and
at least one conduit surface extending from the at least one proximal surface to the at least one distal surface, the at least one conduit surface defining a fluid flow conduit through the nozzle;
wherein an interface between the at least one conduit surface and the at least one distal surface defines an exit orifice of the nozzle; and
wherein the exit orifice exhibits a height extending in a direction along the fluid flow conduit and a width extending in a direction transverse to the height of the exit orifice, a ratio of the height relative to the width being substantially 1.2 or less.
16 . The nozzle of claim 15 , wherein the ratio of the height relative to the width being substantially 0.75 or less, substantially 0.5 or less, or substantially 0.35 or less.
17 . The nozzle of claim 15 , wherein the nozzle comprises one or more lasered microfeatures.
18 . The nozzle of claim 17 , wherein the one or more lasered microfeatures of the nozzle comprises at least one of divots, recesses, or stepped surfaces.
19 . The nozzle of claim 17 , wherein the one or more microfeatures exhibit a dimension that is less than 999 μm, less than 500 μm, less than 100 μm, less than 50 μm, less than 25 μm, less than 10 μm, less than 5 μm, less than 1 μm, less than 500 nm, less than 250 nm, or less than 100 nm.
20 . The nozzle of claim 17 , wherein the one or more microfeatures define at least a portion of an observable rastering pattern.