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US-20260124804-A1 - NOZZLES INCLUDING SUPERHARD MATERIAL AND RELATED ASSEMBLIES AND METHODS

US20260124804A1US 20260124804 A1US20260124804 A1US 20260124804A1US-20260124804-A1

Abstract

Embodiments are directed to nozzles for three-dimensional printing and related nozzle assemblies and methods. An example nozzle includes at least one top surface, at least one bottom surface, and at least one nozzle lateral surface extending from or near the top surface to or near the bottom surface. The nozzle also includes at least one conduit surface defining a conduit. At least a portion of the conduit surface comprise at least one of polycrystalline diamond (“PCD”), polycrystalline cubic boron nitride (“PcBN”), or another suitable superhard material. The nozzle may be attached to a base to form a nozzle assembly.

Inventors

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

Assignees

  • US SYNTHETIC CORPORATION

Dates

Publication Date
20260507
Application Date
20260105

Claims (20)

  1. 1 . A method of attaching a nozzle to a base to form a nozzle assembly for three-dimensional printing, the method comprising: providing the base defining a recess and a passageway extending from the recess to an exterior of the base, the base including at least one wall extending from the rest of the base, the at least one wall defining a portion of the recess; disposing the nozzle in the recess, the nozzle comprising: at least one top surface defining an orifice; at least one bottom surface opposite the at least one top surface, the at least one bottom surface defining an opening; at least one lateral surface; and at least one conduit surface defining a conduit, the at least one conduit surface extending from the orifice to the opening, at least a portion of the at least one conduit surface comprising at least one of polycrystalline diamond or polycrystalline cubic boron nitride, wherein the conduit of the nozzle is configured to be in fluid communication with the passageway when the nozzle is disposed in the recess; and deforming the at least one wall of the base, wherein the deforming attaches the nozzle to the base.
  2. 2 . The method of claim 1 , further comprising selecting the nozzle to include at least one bottom protrusion extending from the at least one bottom surface.
  3. 3 . The method of claim 1 , further comprising selecting the nozzle to include at least one lateral protrusion extending from the at least one lateral surface.
  4. 4 . The method of claim 1 , further comprising: disposing at least one malleable material in the recess before disposing the nozzle in the recess; and deforming the at least one malleable material when the nozzle is secured to the base to fill gaps between the nozzle and the base.
  5. 5 . The method of claim 1 , wherein deforming the at least one wall includes: pressing the at least one wall against a first mold such that the at least one wall exhibits a first tapered shape; and after pressing the at least one wall against the first mold, pressing the at least one wall against a second mold such that the at least one wall exhibits a second tapered shape, wherein the second tapered shape of the at least one wall is less vertical than the first tapered shape of the at least one wall.
  6. 6 . The method of claim 1 , further comprising securing the nozzle in the recess with a brazing process.
  7. 7 . The method of claim 1 , further comprising defining a chamfer between the at least one top surface and at least one of the at least one lateral surface or the at least one conduit surface of the nozzle.
  8. 8 . A method of attaching a nozzle to a base to form a nozzle assembly for three-dimensional printing, the method comprising: providing the base defining a recess and a passageway extending from the recess to an exterior of the base, the base including at least one wall defining a portion of the recess; disposing the nozzle in the recess, the nozzle comprising: at least one top surface defining an orifice; at least one bottom surface opposite the at least one top surface, the at least one bottom surface defining an opening; at least one lateral surface; at least one conduit surface defining a conduit, the at least one conduit surface extending from the orifice to the opening, at least a portion of the at least one conduit surface comprising a superhard material, wherein the conduit of the nozzle is configured to be in fluid communication with the passageway when the nozzle is disposed in the recess; and at least one chamfer extending between the at least one lateral surface and the at least one top surface and/or extending between the at least one conduit surface and the at least one top surface; and securing the nozzle to the base.
  9. 9 . The method of claim 8 , wherein securing the nozzle to the base comprises deforming the at least one wall of the base to attach the nozzle to the base.
  10. 10 . The method of claim 8 , wherein securing the nozzle to the base comprises at least partially securing the nozzle with a braze material.
  11. 11 . The method of claim 10 , further comprising brazing the nozzle to an intermediate structure in the recess.
  12. 12 . The method of claim 8 , wherein the nozzle includes the at least one chamfer extending between the at least one lateral surface and the at least one top surface, the at least one chamfer being polished to exhibit a root mean square (“RMS”) surface roughness that is 3 μm or less.
  13. 13 . The method of claim 8 , wherein the nozzle includes the at least one chamfer extending between the at least one conduit surface and the at least one top surface, the at least one chamfer being polished to exhibit a root mean square (“RMS”) surface roughness that is 100 μm or less.
  14. 14 . A method of attaching a nozzle to a base to form a nozzle assembly for three-dimensional printing, the method comprising: providing a base having a passageway through the base; forming a nozzle from a superhard material, the nozzle including a top surface, a bottom surface, a lateral surface, and an inner conduit surface defining a conduit through the nozzle; defining at least one chamfer on the nozzle between the lateral surface and the top surface and/or between the inner conduit surface and the top surface of the nozzle; and securing the nozzle in a recess defined in the base with a brazing material such that the conduit of the nozzle is in fluid communication with the passageway of the base.
  15. 15 . The method of claim 14 , further comprising deforming the base with at least one bottom protrusion on the nozzle extending outwardly from the bottom surface of the nozzle.
  16. 16 . The method of claim 14 , further comprising deforming the base with at least one lateral protrusion on the nozzle extending outwardly from the lateral surface of the nozzle.
  17. 17 . The method of claim 14 , further comprising: defining the at least one chamfer between the lateral surface and the top surface of the nozzle; and polishing the at least one chamfer being polished to exhibit a root mean square (“RMS”) surface roughness that is 3 μm or less.
  18. 18 . The method of claim 14 , further comprising: defining the at least one chamfer between the inner conduit surface and the top surface of the nozzle; and polishing the at least one chamfer being polished to exhibit a root mean square (“RMS”) surface roughness that is 100 μm or less.
  19. 19 . The method of claim 14 , further comprising brazing the nozzle to an intermediate structure in the recess of the base.
  20. 20 . The method of claim 14 , further comprising forming a substantial entirety of the nozzle from the superhard material.

Description

CROSS REFERENCE TO RELATED APPLICATIONS This application claims is a divisional of U.S. Patent Application Serial No. 17/713,170, titled “NOZZLES INCLUDING POLYCRYSTALLINE DIAMOND OR POLYCRYSTALLINE CUBIC BORON NITRIDE,” filed April 4, 2022, application claims the benefit of the filing date of U.S. Provisional Patent Application Serial No. 63/171,708, titled “NOZZLES INCLUDING POLYCRYSTALLINE DIAMOND OR POLYCRYSTALLINE CUBIC BORON NITRIDE,” filed April 7, 2021, the disclosure of each of which is hereby incorporated by this reference in its entirety. BACKGROUND Three-dimensional (“3D”) printing is a method that includes dispensing a first layer of material onto a platform from a nozzle. Additionally layers of material may be dispensed from the nozzle onto the first and subsequent layers until a three-dimensional object is formed. However, several issues exist with conventional nozzles and conventional nozzle assemblies that include the nozzles, such as unsatisfactory leaking of the material being dispensed and excessive wear on the nozzles. Thus, new and improved nozzles and nozzle assemblies including such nozzles are desirable. SUMMARY In an embodiment, a nozzle assembly for 3D printing is disclosed. The nozzle assembly may include a base defining a recess and a passageway extending from the recess to an exterior of the base. The nozzle assembly may include a nozzle disposed in the recess. The nozzle may include at least one top surface defining an orifice, at least one bottom surface opposite the top surface that defines an opening, at least one lateral surface extending from or near the at least one top surface to or near the at least one bottom surface, and at least one conduit surface defining a conduit. The at least one conduit surface extends from the orifice to the opening. Optionally, at least a portion of the at least one conduit surface comprises at least one of polycrystalline diamond or polycrystalline cubic boron nitride. The conduit of the nozzle is in fluid communication with the passageway when the nozzle is disposed in the recess. The nozzle may be secured to the recess (e.g., by at least one of deforming a portion of the base, threadedly attaching the nozzle to the base, or press-fitting a hollowed-sleeve into the passageway). In an embodiment, a nozzle for 3D printing is disclosed. The nozzle may include at least one top surface defining an orifice, at least one bottom surface opposite the top surface that defines an opening, at least one lateral surface extending from or near the at least one top surface to or near the at least one bottom surface, and at least one conduit surface defining a conduit. The at least one conduit surface extends from or near the orifice to or near the opening. In some embodiments, at least a portion of the at least one conduit surface comprises at least one of polycrystalline diamond or polycrystalline cubic boron nitride. The nozzle may include at least one protrusion extending from at least one of the at least one bottom surface or the at least one lateral surface. Some embodiments may include methods of forming and/or using the nozzles and nozzle assemblies. In an embodiment, a method of attaching a nozzle to a base to form a nozzle assembly for 3D printing is disclosed. The method includes providing the base defining a recess and a passageway extending from the recess to an exterior of the base. The base including at least one wall extending from the rest of the base. The at least one wall defining a portion of the recess. The method also includes disposing the nozzle in the recess. The nozzle includes at least one top surface defining an orifice, at least one bottom surface opposite the top surface that defines an opening, at least one lateral surface, and at least one conduit surface defining a conduit. The at least one conduit surface extends from or near the orifice to or near the opening. In some embodiments, at least a portion of the at least one conduit surface comprises at least one of polycrystalline diamond or polycrystalline cubic boron nitride. The conduit of the nozzle is in fluid communication with the passageway when the nozzle is disposed in the recess. The method further includes deforming the at least one wall. Deforming the at least one wall attaches the nozzle to the base. In some embodiments, methods of using a nozzle in a three-dimensional printing process may include flowing a fluid (e.g., printing material) through a conduit of a nozzle defined by a conduit surface comprising at least one superhard material where the nozzle is fixedly secured to a base portion. Features from any of the disclosed embodiments may be used in combination with one another, without limitation. In addition, other features and advantages of the present disclosure will become apparent to those of ordinary skill in the art through consideration of the following detailed description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS The drawings