Numerical Optimization of Planar Nozzle Shapes for Fused Deposition Modeling

TL;DR

This paper investigates how nozzle shape optimization in FDM 3D printing affects pressure loss, comparing simple angle-based and complex spline-based designs, and finds that simple designs are nearly as effective as complex ones.

Contribution

It introduces a flexible optimization framework for FDM nozzle shapes and systematically compares simple and advanced parametrizations across different conditions.

Findings

Angle-based optimization reveals two local minima in pressure loss.

Spline-based optimization offers marginal pressure loss reduction over angle optimization.

Simple angle optimization captures most of the pressure-loss reduction achievable.

Abstract

Purpose: In fused deposition modeling (FDM), the nozzle plays a critical role in enabling high printing speeds while maintaining precision. Despite its importance, most applications still rely on standard nozzle designs. This work investigates the influence of nozzle geometry on pressure loss inside the nozzle, a key factor in high-speed printing performance. Design/methodology/approach: We focus on optimizing the nozzle shape to minimize the pressure loss and establish a framework that allows both simple angle-based optimization and more advanced spline-based parametrization. To model the polymer melt flow, we use a Giesekus model to account for viscoelastic effects. Findings: For angle-based optimization, the pressure-loss objective exhibits two local minima: one associated with smooth flow and another with pronounced recirculation regions inside the nozzle. While the latter yields a lower pressure drop, such flow patterns are generally undesirable due to increased residence times and the associated risk of material degradation and nozzle clogging. The splinebased parametrization results in only marginal additional reductions in pressure loss compared to angle optimization, while decreasing the manufacturability of the nozzle considerably. Originality/value: This paper presents a comparative study of FDM nozzle shape optimization using a Giesekus model. We introduce a flexible optimization framework that accommodates both simple and advanced geometric parametrizations. The main contribution is the systematic comparison between angle- and spline-based parametrizations across materials and extrusion velocities, showing that most of the achievable pressure-loss reduction is already captured by the simpler and more manufacture-ready angle optimization.