Computational Fluid Dynamics (CFD) Analysis of 3D Printer Nozzle Designs

Additive manufacturing, particularly 3D printing, has gained significant attention recently due to its flexibility, precision, and sustainability. Among the various 3D printing technologies, Fused Deposition Modeling (FDM) stands out as one of the most popular due to its affordability, ease of use, and print quality. However, a major drawback of FDM-based 3D printers is their relatively low print resolution. One of the key factors influencing print quality is the nozzle design, especially its geometry. As a result, numerous studies in literature have focused on improving 3D printing performance by optimizing nozzle design. In this study, we investigated the effects of nozzle geometry from a Computational Fluid Dynamics (CFD) perspective, examining three aspects: die angle, outlet size, and outlet shape. The CFD analysis revealed that the die angle primarily influences the shear stress within the nozzle, while the outlet size has a significant impact on velocity and pressure difference. The outlet shape affects shear stress, velocity, and pressure difference to a lesser extent than the die angle and size.