3D printer nozzle Archives - Perfect 3D Printing Filament

Wear-Resistant Tungsten 3D Printer Nozzle Launched on Kickstarter

Just a few months ago, we learned from 3D°Hex that it would soon be launching a Kickstarter campaign for a new, highly temperature and wear resistant tungsten 3D printing nozzle, called the Tungzzle, that it had been working to develop for about a year. The startup, based in the Ruhr region of western Germany, is focused on designing and manufacturing better 3D printing materials and components in order to solve some of the current problems in the 3D printing industry, and started with the Tungzzle, which, as you may guess from its name, is made of an alloy with 95% pure tungsten content, and not a combination.

We’ve just learned from 3D°Hex that the crowdfunding campaign for its Tungzzle is now live on Kickstarter.

“The most affordable wear and high temperature resistant 3D-Printing nozzle on the market, made completely of tungsten heavy alloy,” the 3D Printing Tungsten Nozzle campaign’s headline claims. “While many new, cutting-edge 3D-Printing nozzles hit the market every few months, there is a huge disparity in their respective qualities. If you want something that is reliable and durable, you need to put some effort into selecting the right technology. You want something that is affordable, of course, but you want also something reliable, that will produce high quality as well.”

The nozzle is the last piece of your machine that touches your print, so it’s important that it can perform reliably. 3D°Hex founders Christopher and Paul explain on the Kickstarter campaign page that when you need an individual printer nozzle for specific tasks, you may be shelling out a high amount of money for something you’ll be using on a lower cost desktop printer. But they say that the Tungzzle combines all the important benefits of these different nozzles into one. This allows the startup to, as it told us in April, create “the ultimate balance between performance and price.”

3D printed part made of carbon fiber-reinforced filament, printed using the 3D°Hex Tungzzle.

Tungsten is an extremely dense (19.3 g / cm3) and hard (7.5 up to 8 on Mohs scale) metal, with high wear resistance and thermal conductivity, and features the highest critical melting point of all refractory metals. All of these properties mean that the Tungzzle, which is made of 95 WNiFe Tungsten heavy alloy, can print with highly abrasive materials, like carbon fiber, without the inside of the nozzle being damaged, and that it can also work with high temperature materials such as PEEK and nylon. Its excellent thermal conductivity allows for better extrusion performance out of your printer, in addition to better temperature calibration effects.

“With steel with a coefficient of 10.8 to 12.5 and brass with a coefficient of 18 to 19, tungsten has one of the lowest expansion coefficients with 4.5 and does not experience an extreme tempering effect, which means that its properties are retained even at long high-pressure temperatures,” the Kickstarter campaign states.

The Kickstarter campaign has plenty of available rewards left, such as the €12 Supporter pack, which comes with a Tungzzle sticker set and a carbon fiber 3D printed 3D°Hex logo, and the €15 3D°Hex supporter t-shirt. The Ultimate Tungzzle Super Early Bird reward is just €29, which saves 55% off the RRP and comes with the Tungzzle itself, which features an M6 thread, 0.4 diameter, and works with 1.75 mm FDM 3D printing filament. A double Tungzzle pack is €74, while a triple pack is €107, and you can purchase a pack of five Tungzzle 3D printer nozzles for €160.

(Images courtesy of 3D°Hex)

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Analyzing Parameters of Pure and Reinforced 3D Printed PLA and ABS Samples

If you want high-quality 3D printed parts, then you need to choose the right print parameters. Research on this topic is ongoing, and the latest comes from the University of Manchester. Chamil Abeykoon, Pimpisut Sri-Amphorn, and Anura Fernando, with the Northwest Composite Centre in the Aerospace Research Institute, published “Optimization of fused deposition modeling parameters for improved PLA and ABS 3D printed structures,” about their work studying various properties and processing conditions of 3D printed specimens made with different materials.

There are multiple variables involved in 3D printing, and changing just one parameter could cause “consequential changes in several other parameters” at the same time. Additionally, the most commonly used FDM printing materials are thermoplastic polymers with low melting points – not ideal for “some high performance applications.”

“Therefore, attempts have been made to improve the properties of printing filaments by adding particles such as short-fibres, nanoparticles and other suitable additives [18]. Thanks to these extensive researches and developments in the area of FDM, fibre-reinforced filaments are becoming popular and are currently available for practical applications,” they explained.

In order to optimize parameters and settings for these new reinforced materials, the team says we need more 3D printing research and development. In their study, they investigated the process using seven infill patterns, five print speeds, and four set nozzle temperatures, and observed and analyzed the mechanical, thermal, and morphological properties.

They used five commercially available materials, with 1.75 mm diameters:

Polylactic acid (PLA)
Acrylonitrile butadiene styrene (ABS)
Carbon fiber-reinforced PLA (CFR-PLA)
Carbon fiber-reinforced ABS (CFR-ABS)
Carbon nanotube-reinforced ABS (CNT-ABS)

The samples were designed with SOLIDWORKS and printed on a MakerBot Replicator 2, MakerBot Replicator 2X, and MakerBot Replicator Z18.

3D CAD images of test specimens: (a) Tensile, (b) Bending, and (c) Compression.

The team studied seven infill patterns – catfill, diamond, hexagonal, Hilbert, linear, moroccocanstar, and sharkfill – and infill densities of 25%, 30%, 40%, 50%, 70%, 90%, and 100%. Two shell layers were used for all samples, and the print bed temperature was between 23-70° for CFR-PLA, and 110°C for the three types of ABS material, to help reduce shrinkage and warping.

“At each test condition of all the types of tests (mechanical, rheological and thermal), 3 test specimens were prepared and tested, and then the average value was taken for the data analysis to improve the accuracy and reliability of the experimental data,” the team wrote.

Appearance of the printed compression test specimens: (a) PLA, (b) ABS, (c) CFR-PLA, (d) CFR-ABS, and (e) CNT-ABS.

First, the 3D printed samples underwent mechanical testing to determine tensile modulus, flexural modulus, and compression properties. Using differential scanning calorimetry (DSC), the researchers measured melting and crystallization behaviors in a liquid nitrogen atmosphere, and found “the volume fractions of the reinforcement and matrix of the composite filaments” with the help of thermal gravimetric analysis (TGA).

Appearance of printed tensile test specimens: (a) PLA, (b) ABS, (c) enlarged view of PLA, and (d) enlarged view of ABS.

Using a thermal imaging camera, they detected how much heat was released as the figure above was printed with 100% infill density, 20 mm/s infill speed, and 215°C set nozzle temperature. Finally, they used scanning electron microscopy (SEM) to observe and perform morphological testing on the surfaces of the 3D printed specimens that were broken during mechanical testing.

Infill density affects the strength of 3D printed parts. By increasing infill density, you then increase the tensile modulus and decrease porosity, which increases the “strength of the mechanical bonding between layers.”

Relationship between tensile modulus and infill density for PLA.

“For pure PLA, parts with 100% infill density obtained the highest Young’s modulus of 1538.05 MPa,” the researchers note.

But, structure gaps can occur more frequently with low infill densities, which reduces part strength. In the figure below, you can see “the changes in porosity of the structure with the infill density.”

3D printed specimens with infill densities: (a) 25% (b) 50% and (c) 100%.

“Of the tested infill speeds from 70 to 110 mm/s; 90 mm/s infill speed gave the highest Young’s modulus for pure PLA,” they wrote.

Print speeds over 90 mm/s could cause polymer filament to melt, and result in poor adhesion and lower strength. To avoid this, the print speed must be compatible with the set nozzle temperature, and an appropriate combination of speed and set nozzle temperature “can reduce the shrinkage of the parts being printed.”

Relationship between tensile modulus and infill speed for PLA.

3D printed PLA samples were tested with the different infill patterns at 50% infill density, 90 mm/s speed, and 215°C set nozzle temperature.

3D printed samples with infill patterns: (a) Linear, (b) Hexagonal, (c) Moroccanstar, (d) Catfill, (e) Sharkfill, (f) Diamond, and (g) Hilbert.

“Among these seven patterns, the linear pattern gave the highest tensile modulus of 990.5 MPa. This can be justified as the linear pattern should have the best layer arrangement (in terms of the bonding between the layers) with the lowest porous structure,” the team explained.

They found that the print temperature has “a significant effect on the tensile modulus.” 215°C provided the best tensile performance, as lower temperatures might cause poor melting, and thus weak bonding. The set nozzle temperature and print speed correlate, and “should be chosen carefully based on the material being used and the part geometry being printed.”

To study the effect on tensile properties, they were printed with the following parameters: 90 mm/s infill speed, linear pattern, 10% infill density, and 215°C set nozzle temperature for PLA, and 230°C for ABS. The researchers found that the tensile modulus of pure PLA (1538.05 MPa) was far higher than for pure ABS.

“In this study, CFR-PLA gave the largest tensile modulus of 2637.29 MPa while pure ABS (919.52 MPs) was the weakest in tensile strength,” they wrote.

Tensile modulus of the five printing materials.

Reinforcing ABS and PLA with fiber causes higher tensile modulus, though pure PLA was stronger than the CNT-ABS.

Even at 90° of bending, the PLA and ABS samples only had a small crack in the middle, and did not break.

3D printed specimen in bending test.

At 1253.62 MPa, the CFR-PLA had the highest bending modulus, while pure PLA was the lowest at 550.16 MPa.

During compression tests, none of the materials were crushed or broken, and pure ABS was found to be the toughest.

“As evident, pure PLA gave the highest compressive strength while the compressive modulus of CFR-PLA (1290.24 MPa) is slightly higher than that of pure PLA (1260.71 MPa) (higher gradient of the liner region). CFR-ABS and CNT-ABS follow the same trend but CNT-ABS is slightly tougher than CFR-ABS,” the team explained. “Pure ABS shows the lowest compressive strength and modulus (478.2 MPa) but shows the most ductile behavior of the five materials.”

Compressive stress-strain curves of test materials.

Finite element analysis (FEA) by ANSYS was used to visualize stress distribution for the tensile, bending, and compression testing of PLA.

Equivalent stress distribution for tensile test.

“The stress distribution shows that a uniform stress is created in the gauge length of the test piece,” they explained.

“Higher compressive loading will cause the material to have internal crack initiations thereby allowing the PLA to buckle excessively.”

The team concluded through DSC analysis that “the strength of the 3D printed samples is dependent upon the set printing parameters and the printing materials more than the crystallisation.” While the infill speeds differ, the glass transition temperature (T_g) of the samples were similar.

“In this study, cooling of 3D printed parts occurred naturally by releasing heat to the surroundings while printing without any control on the cooling rate,” they stated.

DSC curves of PLA parts printed at different set nozzle temperatures.

As expected, the set nozzle temperature did not significantly effect the T_g, and material crystallization at different temperatures didn’t really affect part strength. But, the tensile modulus did change with the temperature.

TGA was used to analyze the weight loss variation of the composite materials against increased print temperature.

TGA diagrams of short fiber-reinforced composite filaments.

“Degradation temperatures (T_d) of these materials can be determined from the mid-point of the descending part of each curve, which is approximately 331.85 °C for PLA. This value showed some sort of agreement to the value reported in commercial PLA data sheets – 353 °C,” they wrote.

Pure PLA typically has a higher Young’s modulus than pure ABS, so it can help to add “a higher volume fraction of reinforcement into the ABS matrix.” Brittle CFR-PLA and CFR-ABS filaments could have their flexibility affected if more carbon fiber is added, which can cause filament feed issues.

Thermal image during 3D printing.

An infrared thermal camera was used to observe 3D printing. The yellow area is the brightest, and hottest: this is where the polymer was extruded from the nozzle. The color changes to orange where the material starts to solidify, and the “red, pink, purple, and blue areas are at lower temperatures, respectively.” The red circle marks the temperature at the printer wall – less than the sample actually being printed.

“SEM images showed that the strength of the printed samples was dependent upon the arrangement of their layers,” the team noted.

Normal and SEM images of fracture surfaces of PLA samples: (a) 25% and (b) 100% infill density.

Observing the fracture surfaces of broken PLA samples with SEM showed that “the air gaps of 25% infill density sample is larger than that of 100% infill density.”

Looking at infill speed with SEM, the team noted that “the best orderliness” comes from 90 mm/s infill speed.

Incompatibility between the material matrix and the reinforcement can cause porosity in the 3D printed samples, but the latter can “contribute in increasing the mechanical properties by bearing the load.” You can see below that the pure PLA has a more regular layer alignment when compared to pure ABS.

SEM images of 3D printed parts at 19X magnification: (a) PLA, (b) ABS, (c) CFR-PLA, (d) CFR-ABS, and (e) CNT-ABS.

CFR-ABS is more porous than CFR-PLA, and both are rougher than the materials in their pure forms.

“Meantime, CNT-ABS shows a better arrangement of individual layers than the other two carbon fibre reinforced materials and also than the pure ABS as well,” they explained.

The last SEM images compare the size of the carbon fiber and carbon nanotube reinforcements. The fracture surface of the CNT-ABS shows some small holes, “due to the embedded carbon nanotubes in the matrix.”

“Compared to the matrix-reinforcement compatibility, both materials show some sort of incompatibility by having cracks and voids between the fibre and matrix,” they wrote.

“On the other hand, although the overall strength of CNT-ABS is improved by CNT particles, the flexibility of this material was decreased compared to the pure ABS as CNT-ABS being more brittle.”

SEM images of fracture surfaces at 1.00 KX magnification: (a) CFR-PLA and (b) CNT-ABS.

They found that the optimal settings to improve the performance of the five 3D printing materials were 100% infill density, 90 mm/s infill speed, 215 °C of set nozzle temperature, and linear infill. Of the five materials, CFR-PLA had the strongest tension, bending, and compression, with the highest modulus.

“Overall, it is obvious that the set printing parameters can significantly influence the mechanical properties of 3D printed parts. It can be claimed that the printing speed and set nozzle temperature should be matched to ensure proper melting of filaments and also to control the material solidification process,” the researchers concluded.

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Massachusetts Researchers Develop In-Line Rheometer for FDM 3D Printing

In-line rheometer nozzle design: (a) custom nozzle, (b) load transfer column, [(c) and (d)] load transfer column plus thermocouple inserted into the nozzle pressure port, (e) custom clamps for the load cell, and (f) full assembly.

Rheology is the study of the flow of matter, and the flow rate of 3D printing materials is fairly important when it comes to the final print. According to a pair of researchers from Massachusetts, it’s actually “the most critical material property” in terms of most polymer melt and liquid processing 3D printing processes, like FDM. It can determine the shear rate along the material flow path, influence melt temperature, create important pressure profiles, determine material output and flow rate, and even influence the final material strength and shape.

The researchers, hailing from the University of Massachusetts Lowell and Saint-Gobain Research North America, recently published a paper, titled “In-line rheological monitoring of fused deposition modeling,” about their work developing an in-line rheometer for the FDM process.

Nozzle dimensions measured by x-ray computed tomography.

The abstract reads, “An in-line rheometer has been incorporated into a fused deposition modeling printer for the first time by designing a modified nozzle with a custom pressure transducer and a thermocouple for measuring the processed melt temperature. Additionally, volumetric flow rates and shear rates were monitored by counting the stepper motor pulses as well as the pulses from a custom filament encoder to account for filament slippage and skipped motor steps. The incorporation of the sensors and the design and development of the in-line rheometer are described; and pressures, temperatures, and viscosities within the 3D printing nozzle are presented. The in-line rheometer was validated against traditional, off-line rotational rheology and capillary rheology measurements by analyzing two polymeric materials: polycarbonate and high-impact polystyrene. A variety of rheological corrections were considered for the in-line rheometer, including entrance effects, non-Newtonian corrections, shear heating, pressure effects, and temperature fluctuations/inaccuracies. Excellent agreement was obtained between the in-line and off-line rheometers after applying the most critical corrections, which were found to be entrance effects, non-Newtonian corrections, and temperature inaccuracies. After applying the appropriate corrections, the in-line rheometer provides an accurate viscosity measurement that can be used for real-time monitoring and process control.”

In-line, or on-line, rheometers, are most often validated by applying rheological corrections, then comparing the on-line measurements to the off-line ones. These corrections are important in order to get accurate viscosity measurements, but according to the paper, “in-line rheometers have yet to be incorporated or studied on FDM to confirm the theoretical calculations or to study the influence of rheology on final properties.”

“This article describes the design of the custom pressure transducer and custom nozzle required for the in-line rheometer. The performance of the rheometer is validated against off-line rheological measurements as well as with an in-line comparison to a capillary rheometer. Finally, a variety of rheological corrections are considered and discussed, including end effects, non-Newtonian flow, viscous dissipation, pressure effects, and temperature corrections,” the researchers wrote.

System of sensors, devices, and connections for in-line rheology and process monitoring.

The researchers did analyze viscous dissipation as well, though it was determined to be negligible and no corrections were applied to the data. A LulzBot TAZ 6 3D printer was used, and the researchers developed a new nozzle system, complete with several custom parts, to create the in-line rheometer. Both the load cell clamps and the nozzles were produced from brass castings of lost wax patterns 3D printed by Shapeways, and polycarbonate (PC) and high-impact polystyrene (HIPS) filaments were both analyzed on the in-line rheometer.

CapRheo/FDMRheo joint setup for verifying FDMRheo pressure measurements against a CapRheo pressure transducer.

The researchers validated the in-line FDM rheometer (FDMRheo) by 3D printing into open space with a stationary nozzle raised 30 cm above the build plate. Capillary rheology (CapRheo) and rotational rheology (RotRheo) were both performed for the HIPS and PC materials. The researchers found that the FDMRheo they designed was able to provide very accurate measurements of viscosity.

“The FDMRheo can collect data across a wide range of temperatures and shear rates to generate a successful Cross-WLF model for analyzing continuous viscosity curves as a function of temperature, shear rate, and pressure. The sensor for measuring the filament feed rate as well as the thermocouple for measuring melt temperature were both critical for the deployment and accuracy of the in-line rheometer. Entrance effects were the most significant correction for obtaining an accurate viscosity, so the Bagley correction should be applied to allow the FDMRheo to be used for real-time process control of the FDM process. For example, a control scheme could be developed to optimize the printing speed while maintaining pressures and viscosities within the ideal processing window,” the researchers concluded. “The FDMRheo is suitable for analyzing the viscosity of new, 3D printable materials to more rapidly introduce new materials to the market; the vision is that the rheometer can enable automatic process optimization and quality assurance using physics-based models for weld fusion (i.e., interlayer strength), residual stress, print density, and shrinkage.”

Co-authors of the paper are Timothy J. Coogan and David O. Kazmer.

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3D Printing News Briefs: November 13, 2018

We should really call today’s 3D Printing News Briefs the formnext 2018 Briefs, as announcements from the show are numerous this week. EnvisionTEC, XYZprinting, BASF, and DSM all introduced new 3D printing materials at the event in Frankfurt today, and in the only news not related to formnext, Imerys Ceramics has announced a new range of ceramic feedstocks.

EnvisionTEC Debuting First 4K 3D Printing System

At formnext, 3D printer manufacturer EnvisionTEC debuted the industry’s first DLP-based 3D printer that uses a true 4K projector with UV optics tuned to the 385 nm wavelength. Available in three production-ready variations, with a gray body and a 2560 x 1600 pixel projector resolution, the Perfactory P4K 3D printer delivers highly accurate parts with an ultra-smooth surface finish. Additionally, the Perfactory P4K, has access to the rest of the Perfactory line’s versatile materials portfolio for production capacity.

“The P4K is the highest resolution advanced DLP printer with the largest build envelope and deploys artificial intelligence in pixel modulation to deliver the highest accuracy parts with the smoothest available surface finish in the 3D printing space. This will deliver the next level of production-grade 3D printing solutions,” said Al Siblani, the CEO of EnvisionTEC.

The new Perfactory P4K will be on display at formnext all week.

XYZprinting Introducing New 3D Printing Materials

Another company introducing new materials at formnext this week is desktop 3D printing brand XYZprinting. In order to expand the capabilities of both domestic and professional grade 3D printers, the company is launching a new antibacterial PLA material, along with copper metallic PLA and Carbon PLA materials. The first of these can destroy up to 99% of bacteria, including E. coli and Staphylococcus aureus, and comes in four colors: white, red, yellow and neon green.

The copper metallic PLA, made of 65% copper powder, is a good alternative for hobbyists when it comes to sculpting metal for ornamental models. The material is being launched in conjunction with XYZprinting’s new nozzle, made of carbon hardened steel. Finally, the new Carbon PLA, which is also compatible with this new nozzle, is made of 10% carbon fiber, and its matte finish is ideal for showing off fine details. You can learn more about these new materials at XYZprinting’s booth D10 in Hall 3.1, where it will also be exhibiting its latest 3D printer, the da Vinci Color AiO, with a 3D scanner and optional laser engraver.

BASF 3D Printing Solutions Presents New Products at formnext

Germany-based BASF 3D Printing Solutions GmbH (B3DPS), a 100% subsidiary of BASF New Business GmbH, is also at formnext this week, to introduce several new materials for photopolymer and laser sintering methods, in addition to announcing some new partnerships and alliances. First, B3DPS is introducing flame-resistant Ultrasint Polyamide PA6 Black FR, Ultrasint PA6 Black LM X085, which is suitable for most current SLS 3D printers, and Ultrasint PP, a polypropylene with great plasticity, low moisture uptake, and resistance to liquids and gases. Additionally, B3DPS has also grouped its photopolymer materials under the new Ultracur3D brand name.

András Marton, Senior Business Development Manager at B3DPS, said, “Our Ultracur3D portfolio enables us to offer customers various UV-curable materials for 3D printing that provide far better mechanical properties and higher long-term stability than most available materials.

“These materials have been developed for functional components that are subject to high stress.”

The subsidiary also announced that it’s partnering with California company Origin and 3D printer manufacturer Photocentric to develop photopolymers and photopolymer 3D printing processes, and working with Chinese 3D printer manufacturer Xunshi Technology, which operates in the US under the name SprintRay, to open up new applications for the Ultracur3D range. Additionally, B3DPS subsidiary Innofil3D is partnering with Jet-Mate Technology in China and US-based M. Holland to distribute plastic filaments. Visit B3DPS at formnext this week at booth F20 in Hall 3.1.

DSM Announces 3D Printing Product Launches

Vent cover used for PIV windtunnel testing, printed in Somos PerFORM Reflect

In today’s final formnext news, science-based company DSM has unveiled two new high-performance materials for 3D printing structural parts. Somos PerFORM Reflect is a groundbreaking new stereolithography material for wind tunnel testing with PIV (Particle Imaging Velocimetry), and saves more than 30% post treatment cost by eliminating the need to apply PIV coatings to printed parts. In addition to helping customers conduct iterations and collect data more quickly, the resin could actually help break speed records for wind tunnel testing.

“Speed is crucial, whether in automotive, aerospace or other transportation design. Eliminating the need to apply PIV coatings is a major breakthrough for customers who are using PIV wind tunnel testing. It allows them to speed up their aerodynamic design optimizations. We are thrilled that our strategy of focusing on helping customers create their applications have enabled us to deliver such tremendous value. Overnight, Somos® PerFORM Reflect will not just set new speed records but new industry standards,” said Hugo da Silva, Vice President of Additive Manufacturing at DSM.

The company’s second new material is the thermoplastic copolyester (TPC) Arnitel ID2060 HT, which is perfect for the FDM 3D printing of structural parts for automotive applications. The material features a balance of prolonged high temperature resistance, flexibility, and chemical resistance against exhaust gas recirculation (EGR) condensate.

Imerys Ceramics Introduces EZ Print 3D Range of Ceramic Feedstocks

As part of the Imerys group, Imerys Ceramics designs, produces, and markets high-performance mineral solutions for the ceramic industries, and is making ceramic 3D printing easy with its new, unique range of ceramic materials called EZ Print 3D.

EZ Print 3D is available as a plug & play cartridge, so users can enjoy efficiency and ease of use when it comes to 3D printing. The materials are also available as a “ready to fill” ceramic feedstock, and have been tested on several 3D printers currently on the market. EZ Print 3D has a low firing temperature of 1220°C that’s compatible with most kiln temperature limits, and the genuine low porosity (<0,5%) of a porcelain. The technology is perfect for tableware and giftware applications, and the company plans to expand EZ Print 3D accordingly as 3D printing adoption grows. Imerys Ceramics also provides technical support and a dedicated team that’s competent in 3D printing to help customers.

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