Apparatus, system and method of operating an additive manufacturing nozzle

Abstract

Apparatuses, systems and methods of providing heat to enable an FDM additive manufacturing nozzle having refined print control and enhanced printing speed. The heating element may include at least one sheath sized to fittedly engage around an outer circumference of the FDM printer nozzle; at least one wire coil at least partially contacting an inner diameter of the sheath; and at least one energy receiver associated with the at least one wire coil.

What is claimed is: 
     
         1 . A heating element for a 3D printer nozzle, comprising:
 at least one sheath comprising an first inner diameter and a first outer diameter, the at least one sheath sized to engage around an outer circumference of the 3D printer nozzle;   at least one wire coil at least partially contacting the first inner diameter of the at least one sheath; and   at least one energy receiver associated with the at least one wire coil.   
     
     
         2 . The heating element of  claim 1 , wherein the at least partially contacting comprises embedded within. 
     
     
         3 . The heating element of  claim 1 , wherein the at least one energy receiver comprises at least one current receiving wire. 
     
     
         4 . The heating element of  claim 1 , wherein the at least one wire coil comprises a nichrome wire. 
     
     
         5 . The heating element of  claim 1 , wherein the at least one wire coil comprises at least a first wire coil and a second wire coil. 
     
     
         6 . The heating element of  claim 5 , wherein the at least two wire coils are at least partially staggered along a longitudinal axis of the 3D printer nozzle. 
     
     
         7 . The heating element of  claim 5 , wherein the first wire coil is embedded in the first sheath and the second wire coil is embedded in a second sheath. 
     
     
         8 . The heating element of  claim 7 , wherein the second sheath is concentrically located about the first sheath. 
     
     
         9 . The heating element of  claim 1 , wherein the at least one wire coil is attachedly coiled about the outer circumference of the 3D printing nozzle, and wherein the at least one sheath slides at least substantially over the at least one wire coil. 
     
     
         10 . The heating element of  claim 1 , wherein the energy receiver comprises at least one of a Newtonian, a convective, and a radiative energy receiver. 
     
     
         11 . The heating element of  claim 1 , further comprising at least one insulating layer between the outer circumference of the 3D printer nozzle and the at least one wire coil. 
     
     
         13 . The heating element of  claim 11 , wherein the insulating layer is between the at least one wire coil and an inner diameter of the at least one sheath. 
     
     
         14 . The heating element of  claim 11 , wherein the insulating layer provides at least one of enhanced thermal coupling, redistribution of heat, and insulation from overheating. 
     
     
         15 . The heating element of  claim 1 , wherein the at least one sheath comprises one of a press fit, a plasma vapor deposit, a plating, and a rolled foil. 
     
     
         16 . The heating element of  claim 1 , further comprising at least one resistance sensor capable of sensing a resistance change in the at least one wire coil as indicative of a level of heating delivered to the 3D printer nozzle. 
     
     
         17 . The heating element of  claim 1 , wherein the at least one sheath comprises a reduced thermal mass. 
     
     
         18 . The heating element of  claim 1 , wherein the at least one energy receiver comprises a thermocouple. 
     
     
         19 . The heating element of  claim 1 , wherein the at least one wire coil comprises a high density winding at a taper portion of the 3D printer nozzle and a lower density winding along a non-taper portion of the  3 d printer nozzle. 
     
     
         20 . The heating element of  claim 1 , wherein the at least one wire coil comprises a wet winding. 
     
     
         21 . The heating element of  claim 1 , further comprising a nozzle temperature sensor embedded in the at least one sheath.