Nozzles, nozzle assemblies, and related methods

Patent metadata

Field	Value
Publication number	US-12403486-B2
Application number	US-202217959657-A
Country	US
Kind code	B2
Filing date	Oct 4, 2022
Priority date	Apr 7, 2021
Publication date	Sep 2, 2025
Grant date	Sep 2, 2025

Abstract

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.

First claim

What is claimed is:

1. A method of forming a nozzle for use in a three-dimensional printing process, the method comprising:
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, the forming the hole into the material on the first side of the material comprising using a laser process to remove at least some of the material;
reorienting the material to expose a second side opposing the first side;
on the 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; and
removing the nozzle from a remaining amount of the material.

2. The method of claim 1 , further comprising shaping 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 1.2 or less.

3. The method of claim 1 , further comprising continuing to expose the second side of the material while forming an exterior of the nozzle.

4. The method of claim 1 , further comprising concurrently forming additional nozzles from the material along with the nozzle.

5. The method of claim 1 , further comprising forming the hole only partially through the material to define a blind hole.

6. A method of forming a nozzle for use in a three-dimensional printing process. the method comprising:
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;
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, wherein forming the through hole into the material on the second side of the material comprises using a laser process to remove at least some of the material; and
removing the nozzle from a remaining amount of the material.

7. The method of claim 6 , wherein using the laser process to remove the at least some of the material comprises laser ablating the at least some of the material.

8. A method of forming a nozzle for use in a three-dimensional printing process. the method comprising:
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:
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, wherein forming the hole into the material on the first side of the material and forming the through hole into the material on the second side of the material comprises laser ablating the material on the first side of the material and on the second side of the material; and
removing the nozzle from a remaining amount of the material.

9. The method of claim 8 , further comprising, after forming the hole on the first side of the material, rotating the material 180 degrees to expose the second side.

10. The method of claim 8 , further comprising defining the exit orifice such that a ratio of a height of the exit orifice relative to a width of the exit orifice is less than 0.5.

11. The method of claim 8 , further comprising defining a chamfer on a distalmost portion of the exit orifice.

12. The method of claim 8 , further comprising forming the nozzle to exhibit a tapered inner surface having 0.1 to 30 degree taper.

13. The method of claim 8 , further comprising forming a plurality of nozzles from at least a portion of the remaining amount of the material.

14. The method of claim 8 , further comprising selecting the material to comprise a polycrystalline diamond table.

15. The method of claim 8 , wherein forming the hole into the material on the first side of the material comprises using the laser ablating to form a blind hole into the material.

16. The method of claim 1 , further comprising forming a plurality of nozzles from at least a portion of the remaining amount of the material.

17. The method of claim 6 , further comprising defining a chamfer on a distalmost portion of the exit orifice.

18. The method of claim 6 , further comprising forming the nozzle to exhibit a tapered inner surface.

19. The method of claim 6 , wherein forming the hole into the material on the first side of the material comprises using the laser process to form a blind hole into the material.

Assignees

• Us Synthetic Corp

Inventors

• Meier Jarrett
• Taylor Harris
• Crockett Jacob
• Schmidt Scott

Classifications

• B33Y99/00

  Subject matter not provided for in other groups of this subclass · CPC title

• B22F12/53

  Nozzles · CPC title

• B28B1/001

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title