Showing papers on "Nozzle published in 2018"

Investigation on lemon juice gel as food material for 3D printing and optimization of printing parameters

Abstract: The aim of this paper is to develop a new 3D printing food constructs based on lemon juice gel system. We investigated the effect of potato starch (10, 12.5, 15, 17.5 and 20 g/100 g) on the rheological properties and mechanical properties of lemon juice gels. Besides, the influence of printing parameters (nozzle height, nozzle diameter, extrusion rate and nozzle movement speed) on the quality of printed products were also studied. The results show that it is suitable to make the size of the nozzle height the same with that of the nozzle diameter, which could not be regarded as a key factor that affects print quality. An equation is proposed to explain the relationship between extrusion rate, nozzle diameter and nozzle movement speed. In this printing system, the 1 mm nozzle diameter, 24 mm3/s extrusion rate and 30 mm/s nozzle movement speed were found to be the optimal parameters to print 3D constructs matching the target geometry with fine resolution, more smooth surface texture, and fewer point defects with no compressed deformation.

A New 3D Printing Strategy by Harnessing Deformation, Instability, and Fracture of Viscoelastic Inks

Abstract: Direct ink writing (DIW) has demonstrated great potential as a multimaterial multifunctional fabrication method in areas as diverse as electronics, structural materials, tissue engineering, and soft robotics. During DIW, viscoelastic inks are extruded out of a 3D printer's nozzle as printed fibers, which are deposited into patterns when the nozzle moves. Hence, the resolution of printed fibers is commonly limited by the nozzle's diameter, and the printed pattern is limited by the motion paths. These limits have severely hampered innovations and applications of DIW 3D printing. Here, a new strategy to exceed the limits of DIW 3D printing by harnessing deformation, instability, and fracture of viscoelastic inks is reported. It is shown that a single nozzle can print fibers with resolution much finer than the nozzle diameter by stretching the extruded ink, and print various thickened or curved patterns with straight nozzle motions by accumulating the ink. A quantitative phase diagram is constructed to rationally select parameters for the new strategy. Further, applications including structures with tunable stiffening, 3D structures with gradient and programmable swelling properties, all printed with a single nozzle are demonstrated. The current work demonstrates that the mechanics of inks plays a critical role in developing 3D printing technology.

Importance of the nozzle-exit boundary-layer state in subsonic turbulent jets

Abstract: To investigate the effects of the nozzle-exit conditions on jet flow and sound fields, large-eddy simulations of an isothermal Mach 0.9 jet issued from a convergent-straight nozzle are performed at a diameter-based Reynolds number of 1 x 10^6. The simulations feature near-wall adaptive mesh refinement, synthetic turbulence and wall modelling inside the nozzle. This leads to fully turbulent nozzle-exit boundary layers and results in significant improvements for the flow field and sound predictions compared with those obtained from the typical approach based on laminar flow in the nozzle. The far-field pressure spectra for the turbulent jet match companion experimental measurements, which use a boundary-layer trip to ensure a turbulent nozzle-exit boundary layer to within 0.5 dB for all relevant angles and frequencies. By contrast, the initially laminar jet results in greater high-frequency noise. For both initially laminar and turbulent jets, decomposition of the radiated noise into azimuthal Fourier modes is performed, and the results show similar azimuthal characteristics for the two jets. The axisymmetric mode is the dominant source of sound at the peak radiation angles and frequencies. The first three azimuthal modes recover more than 97 % of the total acoustic energy at these angles and more than 65 % (i.e. error less than 2 dB) for all angles. For the main azimuthal modes, linear stability analysis of the near-nozzle mean-velocity profiles is conducted in both jets. The analysis suggests that the differences in radiated noise between the initially laminar and turbulent jets are related to the differences in growth rate of the Kelvin–Helmholtz mode in the near-nozzle region.

Numerical modeling of the strand deposition flow in extrusion-based additive manufacturing

Abstract: We propose a numerical model to simulate the extrusion of a strand of semi-molten material on a moving substrate, within the computation fluid dynamics paradigm. According to the literature, the deposition flow of the strands has an impact on the inter-layer bond formation in extrusion-based additive manufacturing, as well as the surface roughness of the fabricated part. Under the assumptions of an isothermal Newtonian fluid and a creeping laminar flow, the deposition flow is controlled by two parameters: the gap distance between the extrusion nozzle and the substrate, and the velocity ratio of the substrate to the average velocity of the flow inside the nozzle. The numerical simulation fully resolves the deposition flow and provides the cross-section of the printed strand. For the first time, we have quantified the effect of the gap distance and the velocity ratio on the size and the shape of the strand. The cross-section of the strand ranges from being almost cylindrical (for a fast printing and with a large gap) to a flat cuboid with rounded edges (for a slow printing and with a small gap), which substantially differs from the idealized cross-section typically assumed in the literature. Finally, we found that the printing force applied by the extruded material on the substrate has a negative linear relationship with the velocity ratio, for a constant gap.

Dimension-Based Design of Melt Electrowritten Scaffolds.

Abstract: The electrohydrodynamic stabilization of direct-written fluid jets is explored to design and manufacture tissue engineering scaffolds based on their desired fiber dimensions. It is demonstrated that melt electrowriting can fabricate a full spectrum of various fibers with discrete diameters (2-50 µm) using a single nozzle. This change in fiber diameter is digitally controlled by combining the mass flow rate to the nozzle with collector speed variations without changing the applied voltage. The greatest spectrum of fiber diameters was achieved by the simultaneous alteration of those parameters during printing. The highest placement accuracy could be achieved when maintaining the collector speed slightly above the critical translation speed. This permits the fabrication of medical-grade poly(e-caprolactone) into complex multimodal and multiphasic scaffolds, using a single nozzle in a single print. This ability to control fiber diameter during printing opens new design opportunities for accurate scaffold fabrication for biomedical applications.

What Determines the Drop Size in Sprays

Abstract: In many instances, sprays are formed from the breakup of liquid jets or sheets. We investigate the different parameters that determine the characteristic drop size in the breakup of sheets. We vary both the spraying parameters, such as the pressure and geometry of the nozzle, and the fluid parameters, such as viscosity and surface tension. The combined results show that the drop size is determined by a competition between fluid inertia and surface tension, which allows for the prediction of the drop size from the Weber number and geometry of the nozzle. Once rescaled with the average drop size, the size distribution is found to be described by a compound gamma distribution with two parameters, n and m, with the former setting the ligament corrugation and the latter the width of the ligament size distribution. Fit values for m indicate that nozzles of a conical type produce ligaments of almost equal size, while the flat fan nozzles produce broader distributed ligament sizes. Values for n show that, for all nozzles, ligaments are very corrugated, which is not unexpected for such spray formation processes. By using high-speed photography of the sprays, the parameters m and n can be directly measured and, indeed, govern the drop-size distribution.

Nozzle condition monitoring in 3D printing

Abstract: 3D printing and particularly fused filament fabrication is widely used for prototyping and fabricating low-cost customized parts. However, current fused filament fabrication 3D printers have limited nozzle condition monitoring techniques to minimize nozzle clogging errors. Nozzle clogging is one of the most significant process errors in current fused filament fabrication 3D printers, and it affects the quality of the prototyped parts in terms of geometry tolerance, surface roughness, and mechanical properties. This paper proposes a nozzle condition monitoring technique in fused filament fabrication 3D printing using a vibration sensor, which is briefly described as follows. First, a bar mount that supports the liquefier in fused filament fabrication extruder was modeled as a beam excited by a system of process forces. The boundary conditions were identified, and the applied forces were analyzed for Direct and Bowden types of fused filament fabrication extruders. Second, a new 3D printer with a fixed extruder and a moving platform was designed and built for conducting nozzle condition monitoring experiments. Third, nozzle clogging was simulated by reducing the nozzle extrusion temperature, which caused partial solidification of the filament around inner walls of the nozzle. Fourth, sets of experiments were performed by measuring the vibrations of a bar mount during extrusion of polylactic acid, acrylonitrile butadiene styrene, and SemiFlex filaments via Direct and Bowden types of fused filament fabrication extruders. Findings of the current study show that nozzle clogging in fused filament fabrication 3D printers can be monitored using an accelerometer sensor by measuring extruder’s bar mount vibrations. The proposed technique can be used efficiently for monitoring nozzle clogging in fused filament fabrication 3D printers as it is based on the fundamental process modeling.

Fused filament fabrication melting model

Abstract: This paper presents an analytical melting model inside the nozzle of a fused filament fabrication process. The model presents the limiting case scenario where the maximum melting rate is controlled by the applied force. Here, instead of having a nozzle filled with polymer melt, the melt is reduced to a melt film at the tip of the filament as it is pushed against the exit of the nozzle. The model uses a mode of melting that is governed by melting with pressure flow melt removal. The model includes effects of initial filament temperatures, heater temperature, applied force, nozzle tip angle, capillary diameter and length as well as rheological and thermal properties. The analytical solution is compared to controlled experiments done on a specially designed set-up. Furthermore, the model is used to assess the effect of nozzle tip angle, heater temperature and initial filament temperature on the melting rate within the nozzle. The comparison between the experiments and the model show that assumptions used for the model development are plausible, and that the model can be used to optimize the melting within a material extrusion additive manufacturing process, as well as predicting the performance of new materials.

Throughput enhancement of parallel step emulsifier devices by shear-free and efficient nozzle clearance

Abstract: Step emulsification is an attractive method for production of monodisperse drops. Its main advantage is the ability to parallelize many step emulsifier nozzles to achieve high production rates. However, step emulsification is sensitive to any obstructions at the nozzle exit. At high production rates, drops can accumulate at nozzle exits, disturb the formation of subsequent drops and impair monodispersity. As a result, parallelized step emulsifier devices typically do not work at maximum productivity. Here a design is introduced that parallelizes hundreds of step emulsifier nozzles, and effectively removes drops from the nozzle exits. The drop clearance is achieved by an open collecting channel, and is aided by buoyancy. Importantly, this clearance method avoids the use of a continuous phase flow for drop clearance and hence no shear is applied on the forming drops. The method works well for a wide range of drops, sizing from 30 to 1000 μm at production rates of 0.03 and 10 L per hour and achieved by 400 and 120 parallelized nozzles respectively.

The effect of liquid target on a nonthermal plasma jet - Imaging, electric fields, visualization of gas flow and optical emission spectroscopy

Abstract: The article describes the complex study of the interaction of a helium plasma jet with distilled water and saline. The discharge development, spatial distribution of the excited species, electric field measurement results and the results of the Schlieren imaging are presented. The results of the experiments showed that the plasma-liquid interaction could be prolonged with the proper choice of the gas composition between the jet nozzle and the target. This depends on the gas flow and the target distance. Increased conductivity of the liquid does not affect the discharge properties significantly. An increase of the gas flow enables an extension of the plasma duration on the liquid surface up to 10 μs, but with a moderate electric field strength in the ionization wave. In contrast, there is a significant enhancement of the electric field on the liquid surface, up to 30 kV cm-1 for low flows, but with a shorter time of the overall plasma liquid interaction. Ignition of the plasma jet induces a gas flow modification and may cause turbulences in the gas flow. A significant influence of the plasma jet causing a mixing in the liquid is also recorded and it is found that the plasma jet ignition changes the direction of the liquid circulation.

Substrate treatment apparatus, gas nozzle, and semiconductor device manufacturing method

Abstract: [Problem] To make it possible to improve uniformity among the surfaces of substrates. [Solution] The present invention is provided with: a treatment chamber for treating a plurality of substrates; and a nozzle for supplying the inside of the treatment chamber with a gas. The nozzle has a slit opened in the lengthwise direction, and the slit is formed to the top of the leading end portion of the nozzle.

Impact of Mechanical and Microstructural Properties of Potato Puree-Food Additive Complexes on Extrusion-Based 3D Printing

Abstract: This paper studies the applicability of extrusion-based 3D printing for constructing novel shapes from potato puree and the effects of four additives (agar, alginate, lecithin, and glycerol) added separately at three concentrations (0.5, 1, 1.5%) on the internal strength, mechanical properties, microstructure, and color of potato puree. The printability of the potato puree and the mixtures was assayed by examining the consistency of the extrusions and the stability and accuracy of the printed patterns. The results indicate that better printing was achieved at a nozzle height of 0.5 cm and a nozzle diameter of 4 mm, with concentrations of alginate and agar between 0.5–1.5% and 0.5–1%, respectively, providing the best printability and end product stability, which was attributed to their respective high mechanical characteristics and specific mechanical energy (SME) values. Scanning electron microscopy (SEM) revealed that more convolutions were induced in the potato puree upon the addition of agar or alginate, which increased the puree stability. 3D printing did not significantly affect the surface color parameters of the final product. This study showed that the 3D printing process is a critical factor for initializing the production of customized healthy products.

Preliminary Investigation of Poly-Ether-Ether-Ketone Based on Fused Deposition Modeling for Medical Applications.

Abstract: Poly-ether-ether-ketone (PEEK) fabricated by fused deposition modeling for medical applications was evaluated in terms of mechanical strength and in vitro cytotoxicity in this study. Orthogonal experiments were firstly designed to investigate the significant factors on tensile strength. Nozzle temperature, platform temperature, and the filament diameter were tightly controlled for improved mechanical strength performance. These sensitive parameters affected the interlayer bonding and solid condition in the samples. Fourier transform infrared (FTIR) spectrometry analysis was secondly conducted to compare the functional groups in PEEK granules, filaments, and printed parts. In vitro cytotoxicity test was carried out at last, and no toxic substances were introduced during the printing process.

Nozzle clogging factors during fused filament fabrication of spherical particle filled polymers

Abstract: Fused filament fabrication with reinforced or filled polymers provides improved material properties compared to ordinary feedstock. A current limitation of these materials is the occurrence of nozzle clogging at higher filler contents. In this work, an experiment is designed to identify the factors causing nozzle clogging. Glass sphere-filled polycarbonate is investigated by varying nozzle and filler diameters, the resin viscosity, the filler content, and the extrusion pressure. Equations identifying nozzle clogging and intermittent clogging conditions are provided. Based on these results, a model for the clogging of sphere-filled polymers is proposed. Last, a mathematical model is derived, which approximates the printability of filled polymers without the preparation of composites. This model is based on the nozzle geometry, the filler type and content, the resin viscosity, and the printer’s maximum extrusion force.

3D printing of extremely viscous materials using ultrasonic vibrations

Abstract: Heterogeneous materials used in biomedical, structural and electronics applications contain a high fraction of solids (>60 vol.%) and exhibit extremely high viscosities (μ > 1000 Pa s), which hinders their 3D printing using existing technologies. This study shows that inducing high-amplitude ultrasonic vibrations within a nozzle imparts sufficient inertial forces to these materials to drastically reduce effective wall friction and flow stresses, enabling their 3D printing with moderate back pressures (