SLS-printed nozzles with different internal geometries were developed to increase the flow rate that limits print speed in FDM printers. The nozzles, reviewed by [Thomas Sanladerer], were tested at high flow rates on a Prusa Core One after turning and drilling 0.4 mm holes. The Fuge design delivered the best result in pressure tests; however, printing the nozzles from the tool-steel-grade MS1 material was a limiting factor in terms of performance.
Why it matters
The importance of the study is that it shows the flow issue limiting production speed in FDM printers can also be addressed through the nozzle’s internal geometry. Comparing different designs on the same printer and using pressure tests offers a concrete method for assessing the impact of geometric choices on performance. However, producing the nozzles from the tool-steel-grade MS1 material makes it difficult to completely separate the results of the design comparison from material-related limitations. Therefore, the key question that remains open is whether the best-performing geometry would deliver the same result if produced from a different material. Finishing processes such as turning and drilling also reveal that this approach is not limited to the printing stage alone.
Background
FDM is not a new name in the FikirPilot archive: we have published 2 news stories mentioning it in the last 90 days; the most recent is dated 9 September 2026.