High-Speed Additive Manufacturing Through High-Aspect-Ratio Nozzles

The feasibility of layer-by-layer manufacturing through high-aspect-ratio (HAR) nozzles for microextrusion of paste to deposit planes has been investigated. Various conditions for paste extrusion, including nozzle moving speed, piston speed, extrusion rate, and distance between the nozzle tip and substrate, have been evaluated. By linking various microextrusion parameters together with the aid of a critical distance concept derived from microextrusion using circular nozzles and addressing the extrusion delay in response to the change of the piston speed and air pocket problems properly, we successfully microextruded single planes, multilayer objects, and larger planes made of multiple smaller planes side by side through HAR nozzles. It is further demonstrated that the X-Y dimensions of an extruded plane in the steady-state extrusion stage are determined by the nozzle travel distance and the length of the HAR nozzle opening if microextrusion is conducted with proper conditions. However, the height of the extruded plane is not only determined by the microextrusion conditions, but also affected by the drying shrinkage of the paste after microextrusion. This demonstration of the feasibility of using a HAR nozzle machine opens the door to manufacture of multimaterial, multilayer devices with high productivity in the near future.