3D Printer Nozzle Clogging Prevention Techniques
12 patents in this list
Updated:
In additive manufacturing, nozzle clogging remains a persistent challenge that affects print quality and machine reliability. Material buildup and thermal degradation within nozzles can create blockages as small as 100 microns, leading to inconsistent extrusion, print failures, and extended machine downtime that impacts manufacturing efficiency.
The fundamental challenge lies in maintaining consistent material flow through microscale orifices while managing the complex thermal and rheological behaviors of printing materials.
This page brings together solutions from recent research—including real-time pressure monitoring systems, integrated self-cleaning mechanisms, automated purge routines, and predictive maintenance approaches. These and other approaches focus on preventing and detecting clogs before they compromise print quality or require manual intervention.
1. Three-Dimensional Shaping Device with Relocatable Nozzle Cleaning Mechanism
SEIKO EPSON CORPORATION, 2023
A three-dimensional shaping device that enables efficient cleaning of nozzles without significantly moving the dispensing unit. The device has a dispensing unit, cleaning mechanism, stage, moving unit, and control unit. The cleaning mechanism includes a cleaning unit with a nozzle purge and brush and a recovery unit. The moving unit moves the cleaning unit to clean the nozzle. This allows short access for cleaning by moving only the cleaning unit relative to the stage versus the entire dispensing unit.
2. 3D Metal Object Printer with Integrated Movable Orifice Cleaning Tool
Xerox Corporation, 2023
A 3D metal object printer that can maintain clean nozzles and orifices during printing to prevent drop defects and satellite drops. The printer uses an orifice cleaning tool that can be moved across the orifice and nozzle surface to remove any adhered metal drops. This allows cleaning without needing to shut down and disassemble the printer.
3. Nozzle with Self-Cleaning Feature and Separate Powder-Coolant Flow Paths for Inner Tube Additive Manufacturing
NANJING UNIVERSITY OF AERONAUTICS AND ASTRONAUTICS, 2023
A nozzle for 3D printing or laser cladding the inner walls of tubes. The nozzle has a self-cleaning function to prevent powder accumulation and maintain quality during inner tube additive manufacturing. The nozzle has separate powder and coolant flow paths, with a partition wall between them. It also has a filter outside the nozzle to collect unused powder.
4. Integrated Mixer-Conveyor-Nozzle Assembly for Rigid Material Extrusion in 3D Printing
Hisys Co., Ltd., Black Buffalo 3D Corporation, 2022
An integrated mixer, conveyor, and nozzle device for use in 3D printers to construct buildings. The device mixes the material, conveys it, and then directly extrudes it from the nozzle without any flexible hoses in between that could cause clogs. The key components are connected together in a single rigid unit.
5. Injection Molding and 3D Printing Apparatus with Pressure-Based Nozzle Anomaly Detection System
TOYOTA JIDOSHA KABUSHIKI KAISHA, 2022
An injection molding machine, 3D printer, and abnormality detection method can detect clogging or other issues in the nozzle during operation. The injection machine has a piston/cylinder resin extruder with a target pressure setting. It compares the target pressure to the measured pressure to detect anomalies. When pressure deviation indicates nozzle blockage or other problems, it can stop printing and store the nozzle position for troubleshooting.
6. 3D Printer Printhead with Integrated Light-Based Nozzle Malfunction Detection System
HEWLETT-PACKARD DEVELOPMENT COMPANY, L.P., 2022
System for detecting malfunctioning nozzles in a 3D printer printhead during printing. The system uses light sources and detectors mounted on the printhead housing to detect droplets as they are fired from the nozzles. This enables real-time detection of malfunctioning nozzles during printing and allows immediate mitigation by stopping printing or redirecting other nozzles to compensate.
7. Inkjet Print Head with Integrated Self-Purging and Fume Blocking Shielding Mask
XJET LTD., 2021
An inkjet printing head design that integrates a self-purging mechanism, sediment prevention, and fumes removal system to improve inkjet printing of solar cells. The design involves adding an additional shielding mask with an opening aligned over the print head nozzle plate. The opening forms a capillary gap with the nozzle plate. During printing, ink is pulsed through the opening. During purging, ink drawn into the capillary gap removes purge ink from the nozzles. The capillary action captures ink, preventing drips. The mask blocks drying fumes.
8. 3D Printer Nozzle with Pressure and Flow Rate Monitoring for Clog Detection
BOND HIGH PERFORMANCE 3D TECHNOLOGY B.V., 2021
Ensuring that nozzles of 3D printers do not clog during use. The printer measures the pressure and flow rate of material inside and outside the nozzle. If these values go out of range, indicative of clogging or wear, the printer signals the need for nozzle maintenance or replacement.
9. 3D Printer Nozzle System with Automatic Fluid Flushing upon Printhead Stoppage Detection
HEWLETT-PACKARD DEVELOPMENT COMPANY, L.P., 2021
Preventing clogging of 3D printer nozzles when the printhead inadvertently stops in the build area. If the printhead is detected as stopped in the build area, the printer will flush fluid through the nozzles to cool the printhead and prevent drying/clogging. This avoids issues like clogging or boiling of fluid in the nozzles if the printhead remains stationary in the hot build area.
10. Integrated Sensor System for Clogged Nozzle Detection and Print Bed Registration in 3D Printers
Daniel Gelbart, Oliver Jason Terry, 2020
Detection of a clogged nozzle and accurate registration of the nozzle to the print bed in a 3D printer. The same sensor is used for both functions.
11. Inkjet Printer Nozzle Shielding Mask with Capillary-Action Gap for Controlled Ink Capture
XJET LTD., 2019
Improving inkjet printer nozzle cleaning and reliability. The printer has a shielding mask with a gap that captures ink when printed but not when purging. This prevents ink accumulation on the nozzle plate. The gap uses capillary action to draw ink into it when printed. But when purging, higher pressure prevents ink from entering the gap.
12. 3D Printer Nozzle Cleaning Device with Flexible Conforming Members and Rotatable Attachment Base
XYZprinting, Inc., Cal-Comp Electronics & Communication Company Limited, Kinpo Electronics, Inc., 2015
A cleaning device for removing residual material from the nozzle of a 3D printer. The device has a plate with flexible cleaning members that match the shape of the nozzle. When the nozzle is lowered, the cleaning members wipe off any residue that could impact subsequent prints. The device can rotate and has a base to be attached to the printer.
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A range of techniques to deal with nozzle clogging in 3D printers are shown in the listed patents. These include automatic cleaning systems that use brushes and flushing fluids, intelligent nozzle designs that detect potential blockages entirely, and real-time pressure and flow rate monitoring.
