When to replace 3d printer nozzle

When choosing your 3D printer, the nozzle size of your 3D printer may have been the last thing on your mind. This is a detail that is often overlooked. But depending on what you need to print, the wrong nozzle diameter can get in the way. nine0005

In this article, we'll take a look at the different 3D printer nozzle sizes and why you should consider this assembly, what materials it's made from, understand the relationship between nozzle size and layer height, and how to measure the actual nozzle diameter.

How does nozzle size affect 3D printing?

Nozzle diameter affects the extrusion width of the 3D printer line. This affects some elements of your model. If you are 3D printing for business (make a lot of orders), you need to make sure your extruder is feeding the right amount of material. If too much material is fed, then more filament is used than is actually required for successful 3D printing. Well, a smaller number can simply lead to marriage. nine0005

Or maybe you're printing different designs, some of them very detailed and intricate, and some more practical (like a replacement doorknob) that just needs to be printed quickly and with maximum durability.

In any case, you will need the correct setting to save time, material and ensure the normal quality of the 3D model.

There is no easy answer to what is the best nozzle size for a 3D printer. You need to weigh what you want to achieve and what elements of the 3D model are most important to you. nine0005

Depending on your 3D printer, the nozzle can be quite easily replaced (most of them are mounted on screws), and buying a package with different sizes will cost you a lot.

Most common 3D printer nozzle options

The most common standard nozzle size is the 0.4mm (or 0.35mm) nozzle used by most modern 3D printer manufacturers. The reason for this is that it is a rather large and yet versatile nozzle size. This means that you can print with exceptional detail in no time. nine0005

With the 0.4 mm 3D printing nozzle you can print up to a layer thickness of only 0.1 mm or up to 0.3 mm. The lower the layer height, the better the detail (on the Z axis) and the larger the layer height, the faster your 3D print will be, but with worse detail quality.

A common misconception is that if someone doesn't get good enough 3D print quality on their printer with a 0.4mm nozzle, they immediately think they need a smaller 3D print nozzle.

Another common smaller size is 0. 25 mm. Some 3D printers offer 0.2mm, 0.15mm, and Mass Portal is even experimenting with 0.1mm 3D printer nozzles. And the experiments are really interesting. Thanks to this miniature nozzle, they were able to print the clock mechanism with excellent detail. nine0005

How is nozzle diameter related to 3D printer resolution?

Theoretically, smaller 3D printer nozzles allow for greater precision. But for many 3D printers, especially cheaper or older models, a smaller extruder nozzle won't necessarily make a difference if your printer doesn't support the higher resolution you need. It's like putting low-profile, high-performance tires on an old classic car - it doesn't make it go faster, and it doesn't necessarily make it better cornering. nine0005

This is also similar to how the specifications of a 3D printer on paper (eg advertised resolution) do not always result in the best print quality of the finished product. Just like Ultimaker and Zortrax have very similar resolutions on paper, but in many actual tests, Zortrax produces better models than Ultimaker 2.

smaller nozzles as resolution across the board is getting better every day. nine0005

Let's look at the pros and cons of 3D printing with smaller nozzles. Some are less obvious than others. Next, we'll look at the larger, underpriced nozzles available. I hope after reading this article you will be able to answer the question: "What nozzle size should I print?".

You probably already guessed that the smaller the nozzle size in the extruder, the more detailed model you can get as a result of 3D printing. The thin nozzle is great for complex figures, or if you need to print very thin walls for aircraft skins, or high transparency models, etc. nine0005

The photo below shows the printed skin of a model aircraft, which was made with a standard 0.4 mm diameter nozzle. If the same skin is printed with a nozzle with a diameter of 0.2 mm, then the weight (and strength) would be halved.

It is worth noting that a 3D printer with a 0.2 mm nozzle feeds half as much material as a 0. 4 mm nozzle. And this actually leads to an increase in print time by the same two times. It should be noted that strength and detail are reciprocals of time. So to get high-quality 3D models using a thin nozzle and high resolution, you will have to be patient (2 times more than when printing with a standard 0.4 extruder :)). In some cases this is justified, in others it is a waste of time...

As a general rule, the smaller the nozzle size, the higher the chance of problems with the 3D printer. Especially if you are using cheap materials - they can work well with low models and thicker nozzles, but if you need detailed models that are printed using a thin nozzle, then you should also be puzzled by buying quality filaments for 3D printing.

Other factors are less obvious when 3D printing with a thin diameter nozzle - for example, protrusions can be problematic. This is because each layer has a smaller width for the next layer. Crossing bridges can also be difficult. nine0005

But there is good news too! Where overhangs form, the caliper material will be much easier to remove if printed with a thin nozzle. Due to the increased accuracy, your slicer can use a minimum amount of material between your model and supports, so they will break off more easily and have fewer damaged pads that need to be sanded.

And finally, the most annoying thing about a thin nozzle is the ease with which it clogs. If you downsize to 0.2mm or even 0.1mm, you'll need a small particle to clog the hotend. You need to be very careful about the cleanliness of your 3D printing material and regularly clean the nozzle of your 3D printer. Otherwise, you will not end up with additional unnecessary problems. nine0005

It is also worth taking the time to understand the relationship between nozzle size and layer thickness. In short, the first parameter determines the horizontal detail (along the x and y axes), and the second adjusts the resolution along the vertical or z axis.

How to measure the nozzle size of a 3D printer?

Although the actual nozzle diameter should be engraved on the side of the nozzle, it is not always possible to read this value if it is already installed in the extruder or if you have been printing with it for some time. After all, there is the concept of wear and you may not be sure that the nozzle is the same size as before. nine0005

To determine what size your nozzle really is, very slowly extrude some material into the air (high speed may change shape or size) at the lowest setting you can feed material at (approximately 1 mm/s). Once cool, use a micrometer if you have one. They are generally more accurate than digital calipers. Keep in mind that the filament will probably expand after being extruded. Poor quality material or an extruder that is too hot (especially if you extrude at 1mm/s) will cause the material to expand more, resulting in inaccurate readings. nine0005

It can also be useful to know the size to which your material expands after extrusion if you are working on getting a really nice and accurate model. So feel free to experiment with higher speeds that are a bit more like your actual 3D printing.

What is the relationship between 3D print layer height and nozzle diameter?

In simple terms, this is the thickness of each line of extruded material that makes up each layer of your model. The thinner the layer height (or layer thickness), the finer the print detail in the Z-axis (the vertical dimension of your model), but the more layers will be required. Increases print time. nine0005

These characteristics are related, but not completely. For example, you can print using a thinner, thicker nozzle if vertical resolution is less important to you. Or you can use a thicker nozzle with a very small layer height. Although in this case, do not get too carried away. To maintain adequate pressure, your layer height should be at least 20% less than your nozzle width - and in most cases, for best 3D printing results, it should be around 50%. nine0005

How to determine the correct distance from the nozzle to the desktop of a 3D printer?

With the correct setting of the distance between the table and the nozzle, the base of the finished model should have an almost perfectly smooth, glassy surface. Many people assume that you need to use a stylus to properly set the distance between the nozzle and the 3D printer bed, but in fact, even that can be too thick. So it's worth thinking in the direction of the already proven table calibration with a piece of paper. You should use thin paper. For example, check paper is a great choice. Place the receipt paper under the nozzle and gradually lower the nozzle down until the receipt paper resists a little when you try to push it out. 3D printing at this height will give the bottom of the model a great look, and in the case of tall models, the print will definitely not go astray. nine0005

What is the maximum 3D print layer height compared to the nozzle size?

You don't necessarily need a layer height calculator on your 3D printer, but typically the maximum layer height is 50% of the nozzle width. In some cases, you can go higher (perhaps 75%), but in this case, you must be aware that you can sacrifice reliability.

It's best to experiment with the parameters of your model if you understand the relationship between the 3D printer's nozzle size and the layer height you'll be using to print. So for a 0.4mm nozzle, you will need to print with a layer height of 0.2mm, or up to 0.3mm. Your minimum should be around 0.1mm. If less, then in fact you just increase the waiting time without much benefit (on the same 0.4 mm nozzle). nine0005

In most cases, it is worth printing thinner layers with smaller nozzle diameters and generally thicker layers with thicker nozzles. Just note that if you are printing with a thicker nozzle diameter and very thin layer height, you will need to lower the extrusion settings in your slicer to prevent overfeeding.

It's also worth noting that no matter the size, you should always make sure you always have a clean nozzle. One of the easiest ways to do this is to use a high quality cleaning floss. You only need to use a few grams of it each time you brush, but this will prevent carbon buildup over time. nine0005

So why should I use a 0.8mm nozzle or thicker?

Similar nozzle sizes were more common on older 3D printers but are making a comeback. It's all about using what you need and nothing more. For a large number of models, the 0.4mm headroom that your 3D printer probably comes with may be overkill in terms of detail.

If you need strength and speed, but detail is less important, then you should use a 0.8 mm or even 1.0 mm nozzle. And don't forget that models printed with a 0.8mm nozzle can be very detailed, as a lot depends on your 3D printer as well. nine0005

The only slight disadvantage may be that you use more material, but with thicker part walls you can probably compensate with less infill.

There is no single optimal nozzle size for all models, you just need to take all factors into account and decide which nozzle size is best for you.

What nozzle size should I use for composite materials?

It is worth noting that composite materials (any particulate filament such as wood filler, copper filler, carbon fiber nylon or glass reinforced nylon) will cause extrusion problems when using a thinner nozzle. nine0005

This is because these filaments contain particles which, although nanosized, can cause problems when passing through nozzles smaller than 0.4 mm. For composite materials, it is better to use nozzles of at least 0.5 mm, and for any metal, glass or carbon fiber materials, you will need a hardened nozzle. The brass nozzle that comes with your 3D printer will most likely not last long and will increase in diameter after a few hours of printing.

A 0.5 mm stainless steel or tungsten nozzle will last much longer for composite materials, but will, of course, be more expensive.

So, if you're still wondering "What size extruder nozzle to choose?", here are the results for a nozzle with a diameter smaller than the standard 0.4 mm:

- worth using for small detailed models if your 3D printer supports high resolution;

- 3D printing can take significantly longer, thicker nozzles can significantly reduce print time; nine0005

- overhangs are more difficult to print, but supports break off more easily;

- you need material from a quality proven manufacturer, otherwise the nozzle can easily become clogged.

How to clean the nozzle of a 3d printer: clean the extruder from plastic

The extruder nozzle is one of the most problematic parts in a 3D printer. It can easily get clogged or clogged. Poor plastic feed will affect the quality of the finished model. Print defects will occur. Sometimes the job is completely stuck as the printer needs a nozzle cleaning. nine0005

Main Causes of Clogged Extruder

Regardless of the type of print head, it can become clogged. The reason for this is the filament or dirt that accumulates inside the knot. Most often, the nozzle becomes clogged when the printer is not used correctly under conditions of:

1. Increased load, when the device works for a long time without stopping.
2. In dusty areas. Sometimes the printing device is placed in a non-residential room or workshop, where cleaning is very rarely carried out. nine0136
3. Wrong print settings. In particular, the use of an unsuitable filament or an erroneously set melting point.

In some cases, the design of the nozzle itself can cause frequent clogging. For example, when the printer comes with an initially defective extruder. The geometry of the nozzle is broken. The device should be returned under warranty or the nozzle should be replaced separately.

Information! The filament itself can cause litter. A common factory defect or a burr on the plastic can cause a cork. nine0005

Pieces of sintered filament

In any case, it is worth carefully studying the problem of blockage and only then proceed to prevention. If you are afraid to damage the device, it is better to take the printer to a service center.

Dust and debris trapped in the nozzle

The first cause is dirt or dust that has entered from outside. Most often, the nozzle becomes clogged with debris for a long time. Dirt can accumulate for months and even years. It sinters on the walls of the nozzle, plaque is formed. Over time, it can cause the filament to get stuck. nine0005

Extruder temperature too high

Beginner 3D makers find that an excessively high melt temperature will help avoid clogging problems. This is an incorrect judgment. When working at an elevated temperature, the plastic is instantly sintered right inside the assembly. Filament jamming occurs. A bottleneck is formed.

Therefore, it is important to observe the temperature regime recommended by the filament manufacturer. Sometimes this figure may differ slightly. Somewhere at +/- 5 ° С. It all depends on the printer model, as well as the extruder itself. The optimum melting point is found experimentally. nine0005

How to clean the 3D printer extruder: step-by-step instructions

You can clean the printer yourself, without going to a specialized workshop. There are several working methods by which you can clean the nozzle. Let's consider each of them step by step.

Clogged extruder nozzle

Manual

The roughest way to clean the extruder. Thin objects are used for it:

• drill with a diameter of up to 0.35 mm; nine0136
• guitar string up to 0.33 mm in diameter;
• leg from diode or transistor.

Special nozzle cleaning tool for different diameters

Cleaning algorithm:

1. Shut off the 3D printer. Wait until the nozzle cools down a bit.
2. Remove filament residue from nozzle tip.
3. Drill or chisel the hole slowly with the tools indicated. Be careful not to make a hole too deep. nine0136
4. Turn on the printer, feed the plastic to print.
5. Repeat the procedure several times until the filament comes out in an even layer.

Some experts advise you to clean the nozzle while the printer is on. This can be done if the primary rubbish has been eliminated.

Attention! Do not use a screwdriver or drill! So you can miscalculate the force and go through the extruder, damaging the plastic capture mechanism. It is better to use a thin drill clamped in pliers. nine0005

Cleaning with a thin tool

Thinner

Sometimes mechanical cleaning is only partially helpful. With a drill, you can remove the cause of the blockage, but there are still plaques or influxes of plastic inside the nozzle. This situation is often encountered when working with ABS. To remove the filament completely, you will need to clean the nozzle in an aggressive environment. For example, in acetone or dichloroethane.

Cleaning algorithm:

1. Turn off the printer, let the extruder cool down a bit. nine0136
2. Unscrew the nozzle, put it in a container with acetone or dichloroethane.
3. Leave the part for 2-3 hours, then remove and clean the nozzle with a needle.

Screw the nozzle onto the print head. Throw out the plastic.

Important! Spare nozzles can be stored in the acetone jar. In this way, they will always be ready for use without pre-cleaning.

Filament

Filament cleaning is one of the safest methods that does not involve intervention in the design of the extruder or partial disassembly of this unit. Two types of plastic are used to clean the nozzle:

1. Filament with higher melting point. A reel with refractory plastic is placed in the printer. It literally pushes the cork out of the extruder.
2. Cleaning plastic. It is usually sold in the form of short sticks or small coils. Its structure resembles nylon. Cleaning filament is the safest way to remove plugs in an extruder.

We recommend using the latter method as an alternative to manual or dry cleaning.

Carbon deposits on the filament

Prevention of clogging - expert advice

To keep the extruder and nozzle in good condition, it is worth following a number of rules:

1. Use the filament melting temperature specified by the manufacturer.

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